1 00:00:02,670 --> 00:00:04,770 Narrator: A PIONEERING TEAM OF ENGINEERS 2 00:00:04,772 --> 00:00:07,940 IS ATTEMPTING TO BUILD A GIANT -- 3 00:00:07,942 --> 00:00:10,843 ONE OF THE BIGGEST AND MOST ADVANCED CRUISE SHIPS 4 00:00:10,845 --> 00:00:12,211 IN THE WORLD. 5 00:00:12,213 --> 00:00:14,880 IT'S LIKE A PUZZLE -- A BIG PUZZLE. 6 00:00:14,882 --> 00:00:16,315 YOU CANNOT MAKE A MISTAKE. 7 00:00:16,317 --> 00:00:19,952 Narrator: COSTING $1 BILLION, THIS GIANT SHIP 8 00:00:19,954 --> 00:00:23,589 WILL CARRY MORE THAN 5,700 PASSENGERS 9 00:00:23,591 --> 00:00:28,227 AND WILL HAVE THE WORLD'S LARGEST L.E.D. PANEL ON A SHIP. 10 00:00:28,229 --> 00:00:33,732 FOR TWO YEARS, THE TEAM BATTLES MOUNTAINS OF METAL... 11 00:00:33,734 --> 00:00:35,968 YOU HAVE TO SOLVE PROBLEM AFTER PROBLEM. 12 00:00:35,970 --> 00:00:39,438 ...TO PRODUCE STATE-OF-THE-ART MACHINERY. 13 00:00:39,440 --> 00:00:44,209 IT'S TIME NOW THAT THE SHIP WORKS AND WORKS WELL. 14 00:00:44,211 --> 00:00:46,578 Narrator: THIS COLOSSAL CRUISE LINER 15 00:00:46,580 --> 00:00:50,215 RANKS IN A LEAGUE OF AMBITIOUS NEW ENGINEERING WONDERS 16 00:00:50,217 --> 00:00:53,352 THAT ARE BIGGER, FASTER, TALLER, 17 00:00:53,354 --> 00:00:58,424 AND MORE ADVANCED THAN ANYTHING EVER CONSTRUCTED BEFORE. 18 00:00:58,426 --> 00:01:02,528 THIS IS THE INSIDE STORY OF THE EXTRAORDINARY CHALLENGE 19 00:01:02,530 --> 00:01:05,097 OF BUILDING THESE GIANTS. 20 00:01:05,099 --> 00:01:08,100 -- Captions by VITAC -- www.vitac.com 21 00:01:08,102 --> 00:01:11,103 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 22 00:01:11,105 --> 00:01:17,643 ♪♪ 23 00:01:17,645 --> 00:01:21,380 IN SAINT-NAZAIRE, FRANCE, IS THE STX YARD -- 24 00:01:21,382 --> 00:01:23,949 ONE OF THE LARGEST SHIPYARDS ON EARTH, 25 00:01:23,951 --> 00:01:28,353 AND ONE OF THE FEW CAPABLE OF BUILDING A VESSEL SO MASSIVE. 26 00:01:28,355 --> 00:01:30,422 Vago: THIS SHIP WILL BE IMPOSSIBLY HUGE. 27 00:01:30,424 --> 00:01:32,825 I MEAN, IN THE LAST 15 YEARS, SHIPS -- 28 00:01:32,827 --> 00:01:34,493 THEY'VE GROWN TREMENDOUSLY. 29 00:01:34,495 --> 00:01:37,763 SO, YES, IT WILL BE BIG. 30 00:01:37,765 --> 00:01:40,232 Narrator: WITH ITS AMBITIOUS SIZE AND SCALE, 31 00:01:40,234 --> 00:01:42,401 THIS NEW PROTOTYPE WILL PUSH THE BOUNDARIES 32 00:01:42,403 --> 00:01:45,737 OF CRUISE-SHIP DESIGN AND ENGINEERING. 33 00:01:45,739 --> 00:01:47,940 SHE IS CALLED MERAVIGLIA 34 00:01:47,942 --> 00:01:50,676 AND IS THE VISION OF PIERFRANCESCO VAGO. 35 00:01:50,678 --> 00:01:54,480 MERAVIGLIA, I THINK, WILL REALLY TURN HEADS. 36 00:01:54,482 --> 00:01:56,515 WE WANTED TO MAKE A STATEMENT. 37 00:01:56,517 --> 00:02:01,086 SHE'S GONNA BE A BIG SHIP, AND WE WANT TO MAKE HER FUN. 38 00:02:01,088 --> 00:02:03,055 WE WANT TO HAVE A LOT OF INNOVATION. 39 00:02:03,057 --> 00:02:05,224 ♪♪ 40 00:02:05,226 --> 00:02:09,661 Narrator: PIERFRANCESCO IS INVESTING $1 BILLION IN THIS OCEAN LINER. 41 00:02:09,663 --> 00:02:12,664 ♪♪ 42 00:02:12,666 --> 00:02:14,900 WE'RE TALKING ABOUT A LOT OF MONEY, 43 00:02:14,902 --> 00:02:16,835 SO I'M CERTAINLY NOT GONNA SAVE, 44 00:02:16,837 --> 00:02:20,506 YOU KNOW, ON INNOVATION, AND I WANT THE LATEST. 45 00:02:22,676 --> 00:02:24,943 Narrator: BUILDING THE GIGANTIC SHIP 46 00:02:24,945 --> 00:02:27,312 IS UP TO SITE MANAGER GAETANO ROLANDO. 47 00:02:27,314 --> 00:02:30,883 HE MUST MAKE SURE THE MERAVIGLIA SETS SAIL ON TIME. 48 00:02:30,885 --> 00:02:33,485 [ HORN HONKS ] 49 00:02:33,487 --> 00:02:36,655 THIS IS A VERY EXCITING CHALLENGE FOR ME 50 00:02:36,657 --> 00:02:41,793 AND FOR ALL OUR TEAM BECAUSE EVERY DAY IS DIFFERENT, 51 00:02:41,795 --> 00:02:43,996 EVERY DAY IS SOMETHING NEW. 52 00:02:43,998 --> 00:02:46,031 ♪♪ 53 00:02:46,033 --> 00:02:48,467 Narrator: GAETANO HAS CONSTRUCTED SIX VESSELS 54 00:02:48,469 --> 00:02:50,502 OVER THE PAST 15 YEARS, 55 00:02:50,504 --> 00:02:53,238 NOTHING NEARLY AS AMBITIOUS AS THIS ONE. 56 00:02:53,240 --> 00:02:56,074 ♪♪ 57 00:02:56,076 --> 00:02:59,144 Rolando: SO, THIS IS THE BIGGEST SHIP I'VE BUILT. 58 00:02:59,146 --> 00:03:05,384 I'M VERY EXCITED FOR THIS BIG CHALLENGE. 59 00:03:05,386 --> 00:03:07,019 Narrator: THIS IS THE GIANT 60 00:03:07,021 --> 00:03:10,322 GAETANO AND A TEAM OF 3,000 SHIPYARD WORKERS 61 00:03:10,324 --> 00:03:13,325 MUST SOMEHOW BUILD. 62 00:03:13,327 --> 00:03:18,597 MEASURING 1,036 FEET LONG AND 214 FEET TALL, 63 00:03:18,599 --> 00:03:22,601 THIS SHIP WILL WEIGH MORE THAN 3 TIMES AS MUCH AS THE TITANIC. 64 00:03:25,005 --> 00:03:28,707 ON BOARD, THEY PLAN TO BUILD 20 BARS AND RESTAURANTS, 65 00:03:28,709 --> 00:03:30,042 TWO THEATERS, 66 00:03:30,044 --> 00:03:32,811 AND FOUR SWIMMING POOLS WITH SLIDES 67 00:03:32,813 --> 00:03:36,582 TO CATER FOR THE 5,700 PASSENGERS 68 00:03:36,584 --> 00:03:41,286 STAYING IN 2,244 CABINS. 69 00:03:41,288 --> 00:03:45,224 INSIDE, FOUR GIANT ENGINES WILL POWER THE SHIP, 70 00:03:45,226 --> 00:03:49,027 PROPELLING TWO ROTATING 190-TON THRUSTERS. 71 00:03:49,029 --> 00:03:52,564 ♪♪ 72 00:03:52,566 --> 00:03:54,366 AT THE HEART OF THE VESSEL WILL BE 73 00:03:54,368 --> 00:03:56,902 A MEDITERRANEAN-STYLE SHOPPING PROMENADE 74 00:03:56,904 --> 00:04:01,873 TOPPED WITH A 262-FOOT LONG L.E.D.-SCREEN CEILING -- 75 00:04:01,875 --> 00:04:06,545 THE LONGEST SCREEN EVER BUILT ON A SHIP. 76 00:04:06,547 --> 00:04:10,616 THE COMPANY HAS BUILT 12 CRUISE SHIPS OVER THE LAST 29 YEARS, 77 00:04:10,618 --> 00:04:13,952 BUT THIS WILL BE THE LARGEST AND MOST ADVANCED LINER 78 00:04:13,954 --> 00:04:16,455 THEY HAVE EVER ATTEMPTED. 79 00:04:16,457 --> 00:04:21,159 ♪♪ 80 00:04:21,161 --> 00:04:23,428 Vago: THE PRESSURE IS HUGE. THE RISK IS HUGE. 81 00:04:23,430 --> 00:04:26,798 YOU KNOW, YOU KEEP A SHIP FOR 30, 50 YEARS, 82 00:04:26,800 --> 00:04:29,768 YOU KNOW, YOU CAN'T MAKE A MISTAKE. 83 00:04:29,770 --> 00:04:31,970 Narrator: TO FILL THE SHIP WITH PASSENGERS, 84 00:04:31,972 --> 00:04:34,373 TICKETS FOR THE MAIDEN VOYAGE HAVE GONE ON SALE 85 00:04:34,375 --> 00:04:39,678 BEFORE THE VESSEL IS COMPLETE, AND IT'S ALREADY SOLD OUT. 86 00:04:39,680 --> 00:04:43,115 CANCELING THIS HIGH-PROFILE JOURNEY WOULD BE A DISASTER -- 87 00:04:43,117 --> 00:04:46,218 COSTING THE COMPANY HUNDREDS OF THOUSANDS OF DOLLARS -- 88 00:04:46,220 --> 00:04:48,220 SO THERE'S NO ROOM FOR DELAYS. 89 00:04:48,222 --> 00:04:51,390 ♪♪ 90 00:04:51,392 --> 00:04:56,595 THE HARDEST PART OF MY JOB IS TO DELIVER THE VESSEL ON TIME. 91 00:04:56,597 --> 00:04:58,463 Narrator: WITH THE CLOCK TICKING, 92 00:04:58,465 --> 00:05:01,533 GAETANO AND THE SHIPYARD HAVE JUST 26 MONTHS 93 00:05:01,535 --> 00:05:05,470 TO BUILD, TEST, AND DELIVER THE MASSIVE SHIP. 94 00:05:05,472 --> 00:05:07,439 EVERY DAY -- DAY BY DAY, 95 00:05:07,441 --> 00:05:11,643 THE PRESSURE ON OUR SHOULDERS COMING. 96 00:05:11,645 --> 00:05:13,478 CONSTRUCTING THIS PROTOTYPE VESSEL 97 00:05:13,480 --> 00:05:17,215 INVOLVES A SERIES OF KEY CHALLENGES. 98 00:05:17,217 --> 00:05:20,319 THIS IS THE PLAN. 99 00:05:20,321 --> 00:05:24,723 THE FIRST TASK IS TO TRANSFORM 39,000 TONS OF STEEL 100 00:05:24,725 --> 00:05:28,126 INTO 50 HUGE SECTIONS CALLED MEGABLOCKS. 101 00:05:28,128 --> 00:05:30,162 ♪♪ 102 00:05:30,164 --> 00:05:34,533 THESE BLOCKS WILL JOIN TOGETHER TO FORM THE SHIP'S HULL. 103 00:05:34,535 --> 00:05:37,235 NEXT, WORKERS MUST BUILD AND ATTACH 104 00:05:37,237 --> 00:05:42,674 TWO SPECIALLY-DESIGNED THRUSTERS CALLED AZIPODS. 105 00:05:42,676 --> 00:05:45,544 THESE CARRY THE VESSELS 28-TON PROPELLERS 106 00:05:45,546 --> 00:05:47,546 THAT WILL PUSH IT THROUGH THE WATER. 107 00:05:47,548 --> 00:05:49,448 ♪♪ 108 00:05:49,450 --> 00:05:52,818 ONCE AFLOAT, THE TEAM THEN NEEDS TO CONSTRUCT AND FURNISH 109 00:05:52,820 --> 00:05:55,721 THE 2,244 CABINS... 110 00:05:55,723 --> 00:05:57,823 ♪♪ 111 00:05:57,825 --> 00:05:59,591 ...EQUIP THE DECKS, 112 00:05:59,593 --> 00:06:02,761 AND INSTALL THE 1,450 PANELS 113 00:06:02,763 --> 00:06:07,165 TO CREATE THE PROMENADE'S ONE-OF-A-KIND L.E.D. CEILING. 114 00:06:07,167 --> 00:06:09,601 IF THEY CAN COMPLETE THE VESSEL ON TIME, 115 00:06:09,603 --> 00:06:12,537 ENGINEERS MUST THEN THOROUGHLY TEST THE SHIP 116 00:06:12,539 --> 00:06:15,674 AND PUT HER THROUGH A SERIES OF GRUELING SEA TRIALS. 117 00:06:15,676 --> 00:06:18,910 ♪♪ 118 00:06:21,849 --> 00:06:27,386 GAETANO AND THE SHIPYARD START WITH 39,000 TONS OF BARE STEEL. 119 00:06:27,388 --> 00:06:29,454 THEY MUST SOMEHOW TRANSFORM IT 120 00:06:29,456 --> 00:06:32,958 INTO THE 50 GIANT MEGABLOCKS THAT FORM THE SHIP'S HULL. 121 00:06:52,579 --> 00:06:58,383 WORKERS FEED EACH SHEET OF STEEL INTO THESE GIANT MACHINES. 122 00:06:58,385 --> 00:07:01,686 THEY FIRE A 32,400-DEGREE FAHRENHEIT 123 00:07:01,688 --> 00:07:06,391 JET OF SUPERHEATED GAS CALLED PLASMA THROUGH THE STEEL. 124 00:07:06,393 --> 00:07:09,327 THIS CUTS THE INDIVIDUAL PIECES OF THE SHIP TO SIZE 125 00:07:09,329 --> 00:07:11,263 WITH ABSOLUTE PRECISION. 126 00:07:27,581 --> 00:07:29,181 THEY BUILD THE BLOCKS 127 00:07:29,183 --> 00:07:33,452 FROM AROUND 300,000 INDIVIDUAL STEEL PIECES. 128 00:07:33,454 --> 00:07:36,354 IT'S A GIANT JIGSAW. 129 00:07:36,356 --> 00:07:38,723 WORKERS MUST SORT AND DELIVER EACH PIECE 130 00:07:38,725 --> 00:07:44,162 TO THE RIGHT WORKSTATION SO IT ENDS UP IN THE CORRECT PLACE. 131 00:07:44,164 --> 00:07:47,799 ANY MIXUPS COULD DELAY WORK ON THE WHOLE PROJECT. 132 00:08:01,114 --> 00:08:05,417 ENGINEERS ASSEMBLE SECTIONS OF THE SHIP IN THESE WORKSHOPS. 133 00:08:05,419 --> 00:08:07,352 THEY PIECE TOGETHER GIANT PANELS 134 00:08:07,354 --> 00:08:10,856 THAT FORM EACH MEGABLOCK UPSIDE DOWN. 135 00:08:10,858 --> 00:08:12,524 ♪♪ 136 00:08:12,526 --> 00:08:15,827 THIS MAKES IT EASIER TO INSTALL THE SHIP'S CRUCIAL SERVICES 137 00:08:15,829 --> 00:08:17,195 INTO THE CEILING -- 138 00:08:17,197 --> 00:08:20,732 THIS INCLUDES 932 MILES OF ELECTRICAL CABLE, 139 00:08:20,734 --> 00:08:26,671 124 MILES OF VENTILATION DUCTS, AND 158 MILES OF PIPEWORK. 140 00:08:28,475 --> 00:08:32,143 EACH COMPLETED PANEL MEASURES ONE DECK HIGH. 141 00:08:32,145 --> 00:08:34,946 ONCE PUT TOGETHER, THE PLAN IS FOR WORKERS 142 00:08:34,948 --> 00:08:38,483 TO PUT IT IN A SPECIAL FRAME TO ALLOW THE YARD'S GIANT CRANE 143 00:08:38,485 --> 00:08:41,052 TO LIFT AND FLIP THE PANEL OVER -- 144 00:08:41,054 --> 00:08:43,555 TURNING IT THE RIGHT WAY UP. 145 00:08:43,557 --> 00:08:47,559 AROUND 20 PANELS MAKE UP EACH MEGABLOCK. 146 00:08:47,561 --> 00:08:51,496 THEN THE CRANE WILL LOWER EACH COMPLETED BLOCK INTO THE DRYDOCK 147 00:08:51,498 --> 00:08:54,065 WHERE WORKERS CAN WELD THEM TOGETHER. 148 00:08:54,067 --> 00:08:57,335 IT TAKES NEARLY 11 WEEKS TO CONSTRUCT THE BLOCKS, 149 00:08:57,337 --> 00:09:00,605 BUT WITH MULTIPLE CREWS BUILDING MORE THAN ONE AT A TIME, 150 00:09:00,607 --> 00:09:02,908 THIS METHOD SHOULD SPEED UP THE TIME IT TAKES 151 00:09:02,910 --> 00:09:05,377 TO BUILD THE VESSEL. 152 00:09:07,314 --> 00:09:09,414 ♪♪ 153 00:09:09,416 --> 00:09:13,285 BUT IMPLEMENTING THIS PLAN IS EASIER SAID THAN DONE, 154 00:09:13,287 --> 00:09:15,921 AND THERE'S ANOTHER BIG PROBLEM. 155 00:09:22,262 --> 00:09:25,497 SO, THEY CALL IN THIS GIANT GANTRY CRANE 156 00:09:25,499 --> 00:09:31,136 TO TURN EACH MASSIVE PANEL OVER AND ASSEMBLE THE MEGABLOCKS. 157 00:09:31,138 --> 00:09:33,672 SOARING 213 FEET TALL 158 00:09:33,674 --> 00:09:37,208 AND WITH A LIFTING CAPACITY OF OVER 1,500 TONS, 159 00:09:37,210 --> 00:09:39,811 THIS IS ONE OF THE BIGGEST CRANES IN EUROPE. 160 00:09:44,618 --> 00:09:48,153 THE CRANE OPERATOR SLOWLY RAISES THIS GIANT PANEL. 161 00:09:48,155 --> 00:09:53,625 ♪♪ 162 00:09:57,731 --> 00:09:59,965 ♪♪ 163 00:10:05,339 --> 00:10:10,342 ♪♪ 164 00:10:16,216 --> 00:10:19,751 ♪♪ 165 00:10:19,753 --> 00:10:22,787 THE PANEL HANGS LIKE A HUGE AIRBORNE SAIL. 166 00:10:22,789 --> 00:10:26,691 A SUDDEN GUST FROM THE ATLANTIC NOW COULD PROVE DISASTROUS. 167 00:10:34,901 --> 00:10:37,802 Narrator: AT ONE OF THE BIGGEST SHIPYARDS ON EARTH, 168 00:10:37,804 --> 00:10:38,970 ENGINEERS ARE BUILDING 169 00:10:38,972 --> 00:10:42,440 THE GARGANTUAN MERAVIGLIA CRUISE SHIP. 170 00:10:42,442 --> 00:10:45,276 BUT AS THEY LIFT THIS 100-TON PANEL, 171 00:10:45,278 --> 00:10:47,946 THEY'RE ALSO BATTLING WINDS OFF THE ATLANTIC. 172 00:10:52,786 --> 00:10:54,552 ♪♪ 173 00:10:59,559 --> 00:11:01,693 [ RADIO CHATTER ] 174 00:11:01,695 --> 00:11:05,864 ♪♪ 175 00:11:05,866 --> 00:11:10,602 ♪♪ 176 00:11:10,604 --> 00:11:14,205 DESPITE THE WINDS, THEY'RE ABLE TO LOWER THIS PANEL DOWN, 177 00:11:14,207 --> 00:11:16,775 WHICH WILL FORM THE BASE OF A NEW MEGABLOCK. 178 00:11:22,249 --> 00:11:27,318 EACH MEGABLOCK THEN TAKES 11 WEEKS TO BUILD. 179 00:11:27,320 --> 00:11:31,456 WORKERS FIT THE BLOCKS TOGETHER TO FORM THE SHIP'S BOW, 180 00:11:31,458 --> 00:11:34,159 CENTRAL HULL... 181 00:11:34,161 --> 00:11:36,294 STERN... 182 00:11:36,296 --> 00:11:39,164 AND THE CAPTAIN'S BRIDGE. 183 00:11:39,166 --> 00:11:41,666 IT TAKES AROUND 11 MONTHS FOR THE SHIPYARD 184 00:11:41,668 --> 00:11:44,769 TO PIECE ALL 50 GIANT MEGABLOCKS TOGETHER 185 00:11:44,771 --> 00:11:47,372 TO FORM THE VESSEL'S CORE SKELETON. 186 00:11:50,077 --> 00:11:53,178 WITH MORE THAN 8 MILES OF JOINTS TO WELD 187 00:11:53,180 --> 00:11:56,681 AND 10 FOOTBALL FIELDS OF BARE METAL TO PAINT, 188 00:11:56,683 --> 00:11:59,584 THE DOCK TEAM HAS THEIR WORK CUT OUT FOR THEM. 189 00:11:59,586 --> 00:12:01,753 ♪♪ 190 00:12:01,755 --> 00:12:05,490 BUT AS THE BARE SKELETON OF THE VESSEL BEGINS TO TAKE SHAPE, 191 00:12:05,492 --> 00:12:09,094 ANOTHER TEAM IS GEARING UP TO START THE MONUMENTAL TASK 192 00:12:09,096 --> 00:12:12,397 OF CONSTRUCTING THE INSIDE OF THE SHIP. 193 00:12:12,399 --> 00:12:16,134 GIUSEPPE MARESCA IS OVERSEEING THE DAUNTING INSTALLATION 194 00:12:16,136 --> 00:12:20,739 OF A STAGGERING 2,244 CABINS. 195 00:12:20,741 --> 00:12:23,975 Maresca: IT'S VERY IMPORTANT FOR US TO HAVE ALL THE CABINS ON BOARD 196 00:12:23,977 --> 00:12:27,245 IN THE RIGHT TIME AND FOR THE DELIVERY DATE, 197 00:12:27,247 --> 00:12:31,950 OTHERWISE, WE WILL HAVE UNHAPPY GUESTS AND UNHAPPY BOSSES. 198 00:12:31,952 --> 00:12:35,186 THE CABINS WILL HAVE AN ACCESS TO A BALCONY. 199 00:12:37,657 --> 00:12:39,390 TO CHECK THE POSITION OF THE CABIN, 200 00:12:39,392 --> 00:12:42,427 WE CAN SEE THE TRACING ON THE FLOOR. 201 00:12:42,429 --> 00:12:45,764 THIS IS WHERE ONE CABIN WILL BE AND THERE ANOTHER ONE, 202 00:12:45,766 --> 00:12:48,933 THERE ANOTHER ONE, THERE ANOTHER ONE. 203 00:12:48,935 --> 00:12:51,803 Narrator: GIUSEPPE FACES AN ENORMOUS PROBLEM -- 204 00:12:51,805 --> 00:12:53,404 IT WOULD TAKE YEARS TO BUILD 205 00:12:53,406 --> 00:12:58,243 AND EQUIP EACH INDIVIDUAL CABIN ON BOARD BY HAND, 206 00:12:58,245 --> 00:13:00,345 AND THE SHIP WOULD NEVER MAKE THE SCHEDULE 207 00:13:00,347 --> 00:13:02,847 FOR ITS MAIDEN VOYAGE. 208 00:13:02,849 --> 00:13:05,650 SO ENGINEERS HAVE BEEN DEVELOPING AN INGENIOUS SOLUTION 209 00:13:05,652 --> 00:13:06,951 TO THIS PROBLEM 210 00:13:06,953 --> 00:13:11,022 AT THIS SPECIAL FACTORY JUST OUTSIDE THE YARD. 211 00:13:11,024 --> 00:13:14,325 WELCOME TO THE CABIN FACTORY. 212 00:13:14,327 --> 00:13:16,461 THIS IS WHERE WE BUILD OUR CABINS. 213 00:13:16,463 --> 00:13:19,764 ♪♪ 214 00:13:19,766 --> 00:13:22,634 EVERY 25 MINUTES WE PRODUCE ONE NEW CABIN. 215 00:13:22,636 --> 00:13:25,737 THAT MEANS THAT IN ONE DAY, 216 00:13:25,739 --> 00:13:28,406 WE HAVE PRODUCED ABOUT 16 CABINS PER DAY. 217 00:13:28,408 --> 00:13:30,708 ♪♪ 218 00:13:30,710 --> 00:13:32,343 INSTEAD OF BUILDING EACH CABIN 219 00:13:32,345 --> 00:13:34,479 FROM THE GROUND UP ON BOARD THE SHIP, 220 00:13:34,481 --> 00:13:37,549 PATRICK'S TEAM IS PRE-ASSEMBLING EACH ROOM 221 00:13:37,551 --> 00:13:42,954 JUST LIKE FLAT-PACKED FURNITURE ON THIS UNIQUE ASSEMBLY LINE. 222 00:13:42,956 --> 00:13:47,458 EACH UNIT STARTS LIFE WITH A WATERTIGHT BATHROOM SHELL. 223 00:13:47,460 --> 00:13:50,128 WORKERS INSTALL THE ELECTRICAL WIRING, 224 00:13:50,130 --> 00:13:53,865 PLUMBING, BED FRAME... 225 00:13:53,867 --> 00:13:56,234 EVEN A DESK. 226 00:13:56,236 --> 00:13:58,770 MERAVIGLIA HAS BEEN QUITE A BIG CHALLENGE FOR US 227 00:13:58,772 --> 00:14:01,573 TO PRODUCE SUCH A LARGE QUANTITY OF CABINS 228 00:14:01,575 --> 00:14:03,842 IN A SMALL PERIOD OF TIME. 229 00:14:03,844 --> 00:14:07,045 WE START WITH A BASE FRAME, AND WE PUT THE WALLS AROUND. 230 00:14:07,047 --> 00:14:09,881 AND THEN WE WILL DO THE ROOF ON THE TOP. 231 00:14:09,883 --> 00:14:11,749 WE'LL PUT THE FURNITURE INSIDE. 232 00:14:11,751 --> 00:14:13,852 I'VE NEVER HAD A SHOWER IN THIS... 233 00:14:13,854 --> 00:14:15,587 BUT MY PRODUCTION MANAGER, YES, 234 00:14:15,589 --> 00:14:18,423 HE HAS ALREADY TESTED THAT ON THE PRODUCTION LINE, YES. 235 00:14:20,126 --> 00:14:22,527 Narrator: THEY INSTALL THE AIR CONDITIONING, 236 00:14:22,529 --> 00:14:24,095 WI-FI POINTS, 237 00:14:24,097 --> 00:14:28,867 AND TOUCH-SENSITIVE LIGHTING TO COMPLETE EACH CABIN UNIT. 238 00:14:28,869 --> 00:14:34,939 HERE, MOST OF THE FURNITURE COMES ALREADY ASSEMBLED 239 00:14:34,941 --> 00:14:39,177 EXCEPT FOR THE BIG FURNITURE THAT WE WILL ASSEMBLE OURSELVES. 240 00:14:39,179 --> 00:14:43,448 AGAIN, ONE WARDROBE EVERY 25 MINUTES. 241 00:14:43,450 --> 00:14:45,516 Narrator: BEFORE FINISHING, THEY NEED TO INSTALL 242 00:14:45,518 --> 00:14:47,452 ONE KEY PIECE OF EQUIPMENT 243 00:14:47,454 --> 00:14:50,989 TO MAKE SURE THAT THE CABINS FIT QUICKLY INTO PLACE ON BOARD. 244 00:14:50,991 --> 00:14:53,057 ♪♪ 245 00:14:53,059 --> 00:14:57,061 SO, HERE WE GO, THIS IS WHERE WE'RE GOING TO CONNECT 246 00:14:57,063 --> 00:14:59,597 THE CABINS TO THE SHIP WITH THAT PLUG. 247 00:14:59,599 --> 00:15:00,932 THIS IS PLUG-N-PLAY. 248 00:15:00,934 --> 00:15:02,667 THE CABIN IS JUST FINISHED, 249 00:15:02,669 --> 00:15:05,169 WE JUST NEED TO CONNECT THE CABINS TO THE SHIP. 250 00:15:05,171 --> 00:15:09,440 AND IT WILL WORK AS SIMPLE AS THAT NOW. 251 00:15:09,442 --> 00:15:12,644 IT WOULD BE IMPOSSIBLE TO PRODUCE MERAVIGLIA ON TIME 252 00:15:12,646 --> 00:15:16,681 IF WE WOULD MOVE 100% OF THE CABIN ON BOARD -- 253 00:15:16,683 --> 00:15:19,250 WITHOUT ANY DOUBT. 254 00:15:19,252 --> 00:15:21,486 Narrator: AFTER A MERE 25 MINUTES, 255 00:15:21,488 --> 00:15:25,323 THE ASSEMBLY OF THIS MODULAR CABIN IS COMPLETE. 256 00:15:25,325 --> 00:15:28,593 ITS NEXT STOP IS THE SHIPYARD. 257 00:15:28,595 --> 00:15:32,430 ♪♪ 258 00:15:32,432 --> 00:15:34,065 BUT THE TEAM MUST FIRST GEAR UP 259 00:15:34,067 --> 00:15:36,467 TO FLOAT THE SHIP TO A DIFFERENT HARBOR 260 00:15:36,469 --> 00:15:39,237 BEFORE WORKERS CAN INSTALL THE VESSEL'S CABINS, 261 00:15:39,239 --> 00:15:41,839 RESTAURANTS, AND ENTERTAINMENT ZONES. 262 00:15:41,841 --> 00:15:44,809 ♪♪ 263 00:15:44,811 --> 00:15:47,178 AND BEFORE THEY MOVE THE SHIP, THEY MUST FIRST FIT 264 00:15:47,180 --> 00:15:49,981 ITS TWO MASSIVE PROPELLERS ONTO THE STERN. 265 00:15:53,553 --> 00:15:56,287 LUIC MARON FACES THE DAUNTING TASK 266 00:15:56,289 --> 00:15:59,257 OF DESIGNING THE COMPLEX PROPULSION UNITS. 267 00:15:59,259 --> 00:16:02,226 THEY MUST BE CAPABLE OF PROPELLING THIS ENORMOUS SHIP 268 00:16:02,228 --> 00:16:04,996 WITHOUT COMPROMISING THE COMFORT OF THE JOURNEY. 269 00:16:25,452 --> 00:16:29,220 THIS IS THE PROBLEM -- WHEN A SHIP'S PROPELLER ROTATES, 270 00:16:29,222 --> 00:16:32,690 IT CREATES A VORTEX OF LOW PRESSURE BEHIND THE BLADES 271 00:16:32,692 --> 00:16:36,160 MADE FROM MILLIONS OF TINY AIR BUBBLES. 272 00:16:36,162 --> 00:16:38,629 THIS PROCESS IS CALLED CAVITATION. 273 00:16:41,267 --> 00:16:42,867 WHEN THESE BUBBLES IMPLODE, 274 00:16:42,869 --> 00:16:45,370 THEY SEND OUT SHOCK WAVES THROUGH THE WATER, 275 00:16:45,372 --> 00:16:49,140 WHICH HIT THE PROPELLER AND THE SHIP'S HULL. 276 00:16:49,142 --> 00:16:51,376 IF ENOUGH BUBBLES IMPLODE AT ONCE, 277 00:16:51,378 --> 00:16:55,513 THIS CAN CAUSE VIBRATIONS THAT RUN THROUGH THE SHIP. 278 00:16:55,515 --> 00:16:57,849 THESE CAN CREATE AN UNCOMFORTABLE RIDE 279 00:16:57,851 --> 00:17:00,385 FOR THE PASSENGERS AND CREW. 280 00:17:16,603 --> 00:17:20,138 WITH THE STAKES HIGH FOR THIS GIGANTIC BILLION-DOLLAR VESSEL, 281 00:17:20,140 --> 00:17:23,007 NO OFF-THE-SHELF PROPELLER DESIGN WILL WORK. 282 00:17:23,009 --> 00:17:26,778 SO LUIC MUST DEVELOP A ONE-OF-A-KIND SOLUTION. 283 00:17:34,854 --> 00:17:36,888 Narrator: ENGINEERS ARE CONSTRUCTING 284 00:17:36,890 --> 00:17:39,424 ONE OF THE LARGEST CRUISE SHIPS EVER CONCEIVED, 285 00:17:39,426 --> 00:17:42,660 BUT TO PREVENT THE VESSEL FROM VIBRATING WHILE AT SEA, 286 00:17:42,662 --> 00:17:44,362 ENGINEER LUIC MARON 287 00:17:44,364 --> 00:17:48,833 HAD TO DEVELOP ONE-OF-A-KIND PROPELLERS. 288 00:17:48,835 --> 00:17:51,135 TO TRY AND MINIMIZE VIBRATION, 289 00:17:51,137 --> 00:17:54,338 HE'S DESIGNED A PROPELLER WITH FIVE BLADES, 290 00:17:54,340 --> 00:17:57,275 PERFECTED THEIR SHAPE, ANGLE, 291 00:17:57,277 --> 00:17:59,844 AND DISTANCE FROM THE HULL, 292 00:17:59,846 --> 00:18:03,147 AND THE SPEED AT WHICH THEY WILL ROTATE 293 00:18:03,149 --> 00:18:04,816 TO MAKE SURE THAT THE SHIP 294 00:18:04,818 --> 00:18:07,018 GLIDES SMOOTHLY THROUGH THE WATER. 295 00:18:07,020 --> 00:18:09,220 ♪♪ 296 00:18:26,272 --> 00:18:28,806 BUT ACTUALLY BUILDING SUCH INTRICATE PROPELLERS 297 00:18:28,808 --> 00:18:30,708 IS NO SIMPLE TASK. 298 00:18:30,710 --> 00:18:34,712 ♪♪ 299 00:18:34,714 --> 00:18:36,714 I LOVE MY JOB FOR SURE. 300 00:18:36,716 --> 00:18:40,318 I LOVE TO MAKE THE BEST PROPELLERS IN THE WORLD. 301 00:18:40,320 --> 00:18:42,153 Narrator: WORKERS CAST THE PROPELLERS 302 00:18:42,155 --> 00:18:44,789 FROM A SPECIAL MOLTEN BRONZE ALLOY -- 303 00:18:44,791 --> 00:18:48,593 A MIXTURE OF COPPER, ALUMINUM, IRON, AND NICKEL. 304 00:18:48,595 --> 00:18:53,164 THE CRUISE PROPELLER BLADES ARE VERY BIG BLADES. 305 00:18:53,166 --> 00:18:56,801 Narrator: THEY CAST THE 28-TON PROPELLER IN SEPARATE PARTS -- 306 00:18:56,803 --> 00:18:59,303 THE BLADES AND THE CENTRAL HUB. 307 00:19:05,778 --> 00:19:09,247 WORKERS FILL A SERIES OF BOXES WITH RESIN-BONDED SAND 308 00:19:09,249 --> 00:19:12,517 TO CREATE THE MOLDS FOR THE BLADES. 309 00:19:12,519 --> 00:19:16,754 Traba: WHAT WE DO HERE IS TO PUT SANDBOX IN FRONT OF THE ROBOT, 310 00:19:16,756 --> 00:19:21,058 AND THEN THE ROBOT WILL BE ABLE TO REMOVE THE SAND 311 00:19:21,060 --> 00:19:24,228 AND CREATE THE FINAL SHAPE OF THE MOLD. 312 00:19:28,368 --> 00:19:31,035 Narrator: THEY MUST POUR THE MOLTEN ALLOY INTO THE MOLD 313 00:19:31,037 --> 00:19:34,005 WITHOUT STOPPING TO AVOID ANY IMPERFECTIONS 314 00:19:34,007 --> 00:19:37,842 THAT COULD COMPROMISE ITS STRENGTH. 315 00:19:37,844 --> 00:19:40,144 WHEN WE ARE POURING, IT'S VERY IMPORTANT 316 00:19:40,146 --> 00:19:43,214 THAT THE MATERIAL IS GOING INSIDE THE PART 317 00:19:43,216 --> 00:19:44,916 WITH THE RIGHT VELOCITY. 318 00:19:44,918 --> 00:19:46,984 OTHERWISE, WE CAN HAVE OXIDES 319 00:19:46,986 --> 00:19:49,987 OR OTHER KIND OF DEFECTS THAT WILL APPEAR. 320 00:19:49,989 --> 00:19:54,058 ♪♪ 321 00:19:54,060 --> 00:19:56,994 Narrator: IT TAKES JUST MINUTES TO FILL THE MOLD, 322 00:19:56,996 --> 00:19:59,130 BUT TWO DAYS FOR THE BLADE TO COOL 323 00:19:59,132 --> 00:20:02,433 AND HARDEN FROM AROUND 2,200 DEGREES FAHRENHEIT. 324 00:20:05,505 --> 00:20:09,507 THEN THEY REMOVE THE BLADE FROM ITS MOLD 325 00:20:09,509 --> 00:20:11,475 AND GRIND ITS SURFACE SMOOTH 326 00:20:11,477 --> 00:20:13,811 TO MAKE SURE IT GLIDES THROUGH THE WATER. 327 00:20:16,015 --> 00:20:18,349 A COMPUTER-GUIDED ROTATING CUTTING HEAD 328 00:20:18,351 --> 00:20:22,520 REMOVES LAYER AFTER LAYER OF UNWANTED MATERIAL. 329 00:20:22,522 --> 00:20:26,791 IT'S VERY IMPORTANT THAT WE BUILD THESE PROPELLERS PRECISELY, 330 00:20:26,793 --> 00:20:29,961 OTHERWISE, WE CAN HAVE BIG IMPERFECTIONS ON THE SURFACE. 331 00:20:29,963 --> 00:20:32,964 AND THIS WILL AFFECT TO THE PERFORMANCE OF THE PROPELLER, 332 00:20:32,966 --> 00:20:36,701 AND THE PASSENGER WILL BE AFFECTED BY THAT. 333 00:20:36,703 --> 00:20:39,870 Narrator: FOR 25 HOURS, THIS CUTTING-EDGE ROBOT 334 00:20:39,872 --> 00:20:42,406 SMOOTHS OVER THE BLADE THOUSANDS OF TIMES, 335 00:20:42,408 --> 00:20:46,744 POLISHING AWAY EVERY LAST DEFECT TO AVOID A BUMPY RIDE. 336 00:20:46,746 --> 00:20:50,248 WHEN WE ACHIEVE THE DELIVERY, 337 00:20:50,250 --> 00:20:54,218 WE FEEL VERY WELL ON THE TEAM. 338 00:20:54,220 --> 00:20:58,256 Narrator: BUT USING PROPELLERS THIS LARGE CREATES ANOTHER BIG PROBLEM -- 339 00:20:58,258 --> 00:21:03,561 BECAUSE THEIR GARGANTUAN SIZE MAKES MANEUVERING DIFFICULT. 340 00:21:03,563 --> 00:21:06,364 THE PROPELLERS ON MOST SHIPS ARE CONNECTED TO THE HULL 341 00:21:06,366 --> 00:21:09,767 IN A FIXED POSITION. 342 00:21:09,769 --> 00:21:13,371 TO STEER THE SHIP, THE CAPTAIN USES A RUDDER, 343 00:21:13,373 --> 00:21:17,508 BUT THIS LIMITS THE VESSEL'S MANEUVERABILITY. 344 00:21:17,510 --> 00:21:20,244 FOR A CRUISE SHIP AS LARGE AS MERAVIGLIA, 345 00:21:20,246 --> 00:21:21,812 NAVIGATING THROUGH THE TIGHT PORTS 346 00:21:21,814 --> 00:21:23,514 AT POPULAR DESTINATIONS 347 00:21:23,516 --> 00:21:26,217 WOULD BE NEARLY IMPOSSIBLE. 348 00:21:26,219 --> 00:21:28,953 TO SOLVE THIS PROBLEM, THE ENGINEERS PLAN TO ATTACH 349 00:21:28,955 --> 00:21:30,521 THESE MASSIVE PROPELLERS 350 00:21:30,523 --> 00:21:35,293 TO TWO GIANT ROTATING THRUSTERS CALLED AZIPODS. 351 00:21:35,295 --> 00:21:41,832 THESE HUGE PODS ARE DESIGNED TO SPIN A FULL 360 DEGREES. 352 00:21:41,834 --> 00:21:45,836 THE ROTATING PODS TOGETHER WITH SMALL THRUSTERS IN THE BOW 353 00:21:45,838 --> 00:21:49,307 SHOULD MAKE CONTROLLING THE SHIP MUCH EASIER 354 00:21:49,309 --> 00:21:52,910 AND ALLOW THIS GIANT TO BREEZE INTO THE TIGHTEST OF PORTS. 355 00:21:57,283 --> 00:22:00,117 TIPPING THE SCALES AT AROUND 190 TONS, 356 00:22:00,119 --> 00:22:03,788 IT TAKES 10 WEEKS TO ASSEMBLE A SINGLE AZIPOD UNIT. 357 00:22:03,790 --> 00:22:08,526 ♪♪ 358 00:22:08,528 --> 00:22:14,565 THE COMBINED PROPELLER AND POD WEIGH ABOUT 220 TONS APIECE. 359 00:22:14,567 --> 00:22:17,034 INSTALLING THEM ONTO THE VESSEL'S STERN 360 00:22:17,036 --> 00:22:18,602 WILL BE A HUGE CHALLENGE. 361 00:22:18,604 --> 00:22:21,272 THE SLIGHTEST DENT CAUSED DURING INSTALLATION 362 00:22:21,274 --> 00:22:24,875 COULD DELAY THIS BILLION-DOLLAR SHIP BY MONTHS. 363 00:22:44,030 --> 00:22:46,364 Narrator: TO PREVENT AN UNCOMFORTABLE JOURNEY, 364 00:22:46,366 --> 00:22:50,401 WORKERS ARE ATTEMPTING TO INSTALL TWO 220-TON AZIPODS 365 00:22:50,403 --> 00:22:54,638 ON THIS MEGA-CRUISE SHIP WITH NO HICCUPS. 366 00:22:54,640 --> 00:22:58,109 THE HUGE CRANE LOWERS THE UNITS DOWN INTO THE DOCK. 367 00:22:58,111 --> 00:23:00,411 ♪♪ 368 00:23:00,413 --> 00:23:03,547 WORKERS THEN CAREFULLY SLIDE THEM UNDERNEATH THE SHIP 369 00:23:03,549 --> 00:23:05,616 BEFORE LOCKING THEM INTO POSITION. 370 00:23:05,618 --> 00:23:09,353 Rolando: SO AFTER NOW, THE PROGRESS IS GOOD ENOUGH, 371 00:23:09,355 --> 00:23:12,990 EVERYTHING IS ACCORDING TO THE SCHEDULE. 372 00:23:12,992 --> 00:23:15,259 Narrator: AND WITH THE PODS ATTACHED, 373 00:23:15,261 --> 00:23:18,662 THE HULL OF MERAVIGLIA IS FINALLY COMPLETE. 374 00:23:20,099 --> 00:23:22,933 ♪♪ 375 00:23:22,935 --> 00:23:28,105 INSIDE, THE VAST 315-FOOT LONG, 2-STORY HIGH PROMENADE 376 00:23:28,107 --> 00:23:31,575 THAT RUNS DOWN THE CENTER OF THE SHIP IS TAKING SHAPE. 377 00:23:31,577 --> 00:23:34,945 ♪♪ 378 00:23:34,947 --> 00:23:38,215 BUT BEFORE THE TEAM CAN INSTALL THE VESSEL'S INTERIOR, 379 00:23:38,217 --> 00:23:41,952 WORKERS MUST MOVE THE SHIP TO THE HARBOR WHERE THE CABINS ARE. 380 00:23:41,954 --> 00:23:44,855 ♪♪ 381 00:23:44,857 --> 00:23:47,658 TO DO THIS, THEY MUST FLOAT THE PROTOTYPE VESSEL 382 00:23:47,660 --> 00:23:49,393 FOR THE FIRST TIME. 383 00:23:51,898 --> 00:23:55,032 THIS IS A MAJOR MILESTONE FOR THE COMPANY BOSSES 384 00:23:55,034 --> 00:23:57,334 WHO'VE ARRIVED TO WITNESS THE EVENT. 385 00:23:57,336 --> 00:24:00,237 ♪♪ 386 00:24:00,239 --> 00:24:03,841 IT TAKES EIGHT HOURS TO FILL THE IMMENSE DRYDOCK. 387 00:24:03,843 --> 00:24:09,413 ♪♪ 388 00:24:09,415 --> 00:24:13,350 AND LATER THAT NIGHT, SHE'S FLOATING AND READY TO MOVE. 389 00:24:18,858 --> 00:24:22,460 MERAVIGLIA IS SO BIG, IT TAKES FIVE TUGBOATS 390 00:24:22,462 --> 00:24:25,196 TO CAREFULLY TOW HER TO HER NEW BERTH. 391 00:24:40,012 --> 00:24:42,680 ♪♪ 392 00:24:42,682 --> 00:24:45,716 GIUSEPPE'S TEAM NOW HAS THEIR WORK CUT OUT. 393 00:24:45,718 --> 00:24:49,887 THEY HAVE TO START PUTTING IN THE 2,244 CABIN UNITS 394 00:24:49,889 --> 00:24:52,957 CONSTANTLY DELIVERED TO THE HARBOR EACH DAY. 395 00:24:55,795 --> 00:24:57,495 Maresca: IT'S A MASSIVE CHALLENGE 396 00:24:57,497 --> 00:24:59,497 TO GET ALL THE CABINS INSTALLED IN TIME. 397 00:24:59,499 --> 00:25:03,400 FROM 6:00 IN THE MORNING, WE WILL HAVE A TRUCK COMING HERE 398 00:25:03,402 --> 00:25:06,871 AND CABINS LOADING AND LOADING AND LOADING. 399 00:25:06,873 --> 00:25:10,074 Narrator: TO KEEP PACE WITH THE RELENTLESS SUPPLY OF CABINS, 400 00:25:10,076 --> 00:25:13,143 GIUSEPPE AND THE TEAM PLAN TO USE AN INGENIOUS TECHNIQUE 401 00:25:13,145 --> 00:25:14,645 TO INSTALL THEM. 402 00:25:14,647 --> 00:25:17,615 ♪♪ 403 00:25:17,617 --> 00:25:20,684 SPECIAL HOLES IN THE SIDE OF THE SHIP PROVIDE ACCESS 404 00:25:20,686 --> 00:25:23,187 TO SLIDE THE CABINS ON BOARD QUICKLY. 405 00:25:23,189 --> 00:25:29,126 ♪♪ 406 00:25:29,128 --> 00:25:32,162 THE NEXT STEP IS TO SECURE A GIANT ELEVATOR 407 00:25:32,164 --> 00:25:35,366 ONTO THE OUTSIDE OF THE SHIP TO REACH THEM, 408 00:25:35,368 --> 00:25:40,237 WHICH WILL HELP LOAD AND LIFT EACH CABIN ONTO THE SHIP. 409 00:25:40,239 --> 00:25:45,109 SPECIAL ROLLERS ALLOW THE TEAM TO PUSH THE CABINS ON BOARD, 410 00:25:45,111 --> 00:25:48,078 SQUEEZING THEM THROUGH DIVIDING WALLS, 411 00:25:48,080 --> 00:25:50,648 AND AROUND THE TIGHT CORNERS 412 00:25:50,650 --> 00:25:53,217 SO THE WORKERS CAN ULTIMATELY SLIDE THEM 413 00:25:53,219 --> 00:25:56,053 INTO THE CORRECT SPOT. 414 00:25:56,055 --> 00:25:59,189 IT'S A BIT LIKE UNWRAPPING A NEW CHRISTMAS PRESENT EVERY DAY. 415 00:25:59,191 --> 00:26:02,626 ♪♪ 416 00:26:02,628 --> 00:26:06,530 ♪♪ 417 00:26:06,532 --> 00:26:07,998 THIS IS WHERE WE GET OFF. 418 00:26:08,000 --> 00:26:10,668 ♪♪ 419 00:26:10,670 --> 00:26:12,436 STOP. 420 00:26:12,438 --> 00:26:14,171 PUSH, PUSH. 421 00:26:14,173 --> 00:26:16,373 Narrator: IT'S A TIGHT SQUEEZE TO GUIDE 422 00:26:16,375 --> 00:26:19,476 EACH OF THE 1 1/2-TON CABINS THROUGH THE MAZE OF EQUIPMENT 423 00:26:19,478 --> 00:26:22,313 AND WORKERS THAT CRAM THE INSIDE OF THE VESSEL. 424 00:26:22,315 --> 00:26:25,015 ONE OF THE BIGGEST PROBLEMS IS THE SPACE 425 00:26:25,017 --> 00:26:28,185 TO PUT THE CABIN IN POSITION. 426 00:26:28,187 --> 00:26:31,555 AT SUMMERTIME LIKE THIS, IT'S A LOT OF HARD WORK. 427 00:26:31,557 --> 00:26:37,461 ♪♪ 428 00:26:37,463 --> 00:26:38,696 PULL! 429 00:26:41,233 --> 00:26:43,334 Narrator: IF A SINGLE CABIN GETS DAMAGED, 430 00:26:43,336 --> 00:26:45,035 IT COULD HOLD UP THE INSTALLATION 431 00:26:45,037 --> 00:26:48,372 OF AN ENTIRE DECK OF ROOMS. 432 00:26:48,374 --> 00:26:51,408 ALL THE WORK ONBOARD ARE CONNECTED 433 00:26:51,410 --> 00:26:55,412 SO WE CANNOT HAVE DELAY. 434 00:26:55,414 --> 00:26:56,614 THIS IS INSIDE OF THE CABIN. 435 00:26:56,616 --> 00:27:00,317 HERE WE HAVE THE TOILET, THIS IS THE WARDROBE, 436 00:27:00,319 --> 00:27:03,087 AND HERE WE HAVE THE BEDS. 437 00:27:03,089 --> 00:27:05,689 THERE ARE NO VISIBLE DAMAGE FROM THE TRANSPORTATION. 438 00:27:05,691 --> 00:27:08,225 YES, CABIN IS FINE. 439 00:27:10,429 --> 00:27:12,129 ANOTHER ONE DOWN, AND WE HAVE 440 00:27:12,131 --> 00:27:15,366 STILL MORE 1,000 TO PUT ON BOARD. 441 00:27:15,368 --> 00:27:18,235 Narrator: WHILE GIUSEPPE'S TEAM MUST KICK IT UP A NOTCH... 442 00:27:21,073 --> 00:27:22,539 ...ON THE LOWER DECKS, 443 00:27:22,541 --> 00:27:26,143 WORKERS ARE RACING TO BUILD THE SHIP'S CAVERNOUS PROMENADE. 444 00:27:28,914 --> 00:27:30,581 THIS SPACE IS BEING DESIGNED 445 00:27:30,583 --> 00:27:34,385 TO LOOK LIKE A MEDITERRANEAN-STYLE SEAFRONT. 446 00:27:34,387 --> 00:27:36,754 THE 2-STORY HIGH PROMENADE WILL BE FILLED 447 00:27:36,756 --> 00:27:39,923 WITH SHOPS, RESTAURANTS, AND CAFéS. 448 00:27:59,211 --> 00:28:03,547 THERE'S A HUGE AMOUNT OF WORK FOR THE TEAM STILL TO DO. 449 00:28:03,549 --> 00:28:05,616 THEIR BIGGEST JOB IS INSTALLING 450 00:28:05,618 --> 00:28:08,719 THE SHIP'S GIANT, DISTINCTIVE L.E.D. CEILING. 451 00:28:30,776 --> 00:28:32,776 Narrator: INSTEAD OF A STANDARD GLASS SKYLIGHT 452 00:28:32,778 --> 00:28:34,745 TO COVER THE PROMENADE CEILING, 453 00:28:34,747 --> 00:28:39,016 THE TEAM PLANS TO BREAK WITH TRADITION. 454 00:28:39,018 --> 00:28:41,185 THEY'RE PREPARING TO INSTALL 455 00:28:41,187 --> 00:28:44,722 A NEVER-BEFORE-ATTEMPTED CURVED L.E.D. SCREEN 456 00:28:44,724 --> 00:28:47,124 DESIGNED AT 262 FEET LONG 457 00:28:47,126 --> 00:28:49,993 AND RUNNING THE LENGTH OF THE PROMENADE. 458 00:28:49,995 --> 00:28:52,763 INSTALLING IT WON'T BE EASY, 459 00:28:52,765 --> 00:28:55,165 AND WORKERS MUST CAREFULLY PIECE TOGETHER 460 00:28:55,167 --> 00:28:59,636 1,450 INDIVIDUAL L.E.D. PANELS 461 00:28:59,638 --> 00:29:04,274 TO CREATE THE CURVED, DOMELIKE STRUCTURE. 462 00:29:04,276 --> 00:29:06,810 ONCE COMPLETE, THIS L.E.D. SCREEN 463 00:29:06,812 --> 00:29:08,445 SHOULD BE ABLE TO DISPLAY ANYTHING 464 00:29:08,447 --> 00:29:11,081 THE SHIP'S CREW DESIRES -- 465 00:29:11,083 --> 00:29:14,952 CHANGING THE AMBIENCE OF THE ENTIRE PROMENADE 466 00:29:14,954 --> 00:29:17,454 AT THE TOUCH OF A BUTTON. 467 00:29:17,456 --> 00:29:19,323 ♪♪ 468 00:29:33,372 --> 00:29:35,672 ♪♪ 469 00:29:35,674 --> 00:29:38,075 BUT PUTTING IT TOGETHER IS NOT EASY. 470 00:29:38,077 --> 00:29:42,813 IT TAKES THREE MONTHS TO INSTALL ALL 1,450 L.E.D. PANELS 471 00:29:42,815 --> 00:29:44,815 ON THE GIANT, CURVED FRAME. 472 00:29:44,817 --> 00:29:48,218 ♪♪ 473 00:29:48,220 --> 00:29:51,021 THOUSANDS OF CABLES CONNECT THE PANELS TOGETHER. 474 00:29:51,023 --> 00:29:54,925 ♪♪ 475 00:29:54,927 --> 00:29:58,195 IF JUST A SINGLE CABLE IS INCORRECTLY CONNECTED, 476 00:29:58,197 --> 00:30:01,965 THE SCREEN WON'T FUNCTION PROPERLY. 477 00:30:01,967 --> 00:30:05,803 WITH ALL THE PANELS IN PLACE, IT'S TIME FOR THE BIG TEST -- 478 00:30:05,805 --> 00:30:10,474 WILL ALL THE SECTIONS OF THE 262-FOOT-LONG SCREEN LIGHT UP? 479 00:30:10,476 --> 00:30:14,745 WHAT WE ARE LOOKING AT TODAY IS TO HAVE A COMPLETE 480 00:30:14,747 --> 00:30:19,116 AND FULL IMAGE ON ALL THE VAULT WITHOUT ANY PROBLEM -- 481 00:30:19,118 --> 00:30:21,718 WITHOUT ANY PIXEL MISSING. 482 00:30:21,720 --> 00:30:24,755 OF COURSE, THE EXPECTATION OF THE OWNER 483 00:30:24,757 --> 00:30:26,957 IS TO HAVE A PERFECT PICTURE 484 00:30:26,959 --> 00:30:29,459 FROM THE BEGINNING TO THE END OF THE VAULT. 485 00:30:29,461 --> 00:30:33,263 SO, A VERY BEAUTIFUL CHALLENGE FOR US, 486 00:30:33,265 --> 00:30:37,701 AND LET'S SEE NOW WHAT HAPPENS. 487 00:30:46,245 --> 00:30:48,879 Narrator: BUT IT'S NOT LONG BEFORE THEY RUN INTO TROUBLE. 488 00:31:01,493 --> 00:31:04,228 Baldin: WE HAVE ONE BIG BLACK HOLE. 489 00:31:04,230 --> 00:31:07,431 Narrator: THE TEAM TRIES TO TRACK DOWN THE CAUSE OF THE PROBLEM. 490 00:31:10,302 --> 00:31:12,936 YES. NOTHING CHANGED. 491 00:31:12,938 --> 00:31:14,371 NO, NO, NO. 492 00:31:19,812 --> 00:31:23,347 WITH THE MAIDEN VOYAGE JUST 15 WEEKS AWAY, 493 00:31:23,349 --> 00:31:26,383 CAN THEY IDENTIFY THE PROBLEM WITHOUT DELAYS? 494 00:31:35,861 --> 00:31:37,928 Narrator: WITH ONLY 15 WEEKS 495 00:31:37,930 --> 00:31:41,398 UNTIL ONE OF THE PLANET'S LARGEST CRUISE SHIPS SETS SAIL, 496 00:31:41,400 --> 00:31:44,301 THE ENGINEERS ARE WORKING TO FIX A MAJOR GLITCH 497 00:31:44,303 --> 00:31:47,037 WITH ITS DISTINCTIVE L.E.D. CEILING. 498 00:31:47,039 --> 00:31:50,107 WE ARE SOLVING PROBLEM AFTER PROBLEM. 499 00:31:50,109 --> 00:31:51,909 WHEN YOU FIND THE PROBLEM, YOU HAVE TO SOLVE IT 500 00:31:51,911 --> 00:31:54,044 AND THEN GO TO THE NEXT STEP. 501 00:31:54,046 --> 00:31:56,914 Narrator: THEY SOON FIGURE OUT WHY THE PANEL ISN'T WORKING. 502 00:32:04,323 --> 00:32:07,457 A REPLACEMENT CABLE FIXES THE GLITCHES 503 00:32:07,459 --> 00:32:09,960 WITH THE SHIP'S UNIQUE L.E.D. CEILING. 504 00:32:09,962 --> 00:32:15,999 AS YOU CAN SEE, THE VIDEO AND THE PICTURE ARE SENT CORRECTLY 505 00:32:16,001 --> 00:32:17,567 TO ALL THESE L.E.D. PANELS. 506 00:32:17,569 --> 00:32:20,637 SO, YES, IT'S VERY GOOD 507 00:32:20,639 --> 00:32:24,341 AND WE ARE VERY HAPPY WITH THIS RESOLUTION. 508 00:32:26,645 --> 00:32:29,046 Narrator: THERE ARE NOW JUST NINE WEEKS TO GO 509 00:32:29,048 --> 00:32:30,847 UNTIL THE CRUISE SHIP MERAVIGLIA 510 00:32:30,849 --> 00:32:34,651 SETS SAIL ON HER MAIDEN VOYAGE. 511 00:32:34,653 --> 00:32:37,087 BUT BEFORE THEY COMPLETE THE INSTALLATION, 512 00:32:37,089 --> 00:32:38,855 THE SHIP NEEDS TO LEAVE ITS BERTH 513 00:32:38,857 --> 00:32:41,892 FOR A CRUCIAL SERIES OF TESTS. 514 00:32:41,894 --> 00:32:44,394 VERY EXCITING, YES. 515 00:32:44,396 --> 00:32:48,899 WE'LL BE THREE DAYS WITHOUT SLEEPING FOR SURE. 516 00:32:48,901 --> 00:32:52,502 Narrator: 390 ENGINEERS, MECHANICS, AND CREW 517 00:32:52,504 --> 00:32:54,604 ARE BOARDING THE SHIP TO TAKE IT OUT 518 00:32:54,606 --> 00:32:58,742 ONTO THE OPEN OCEAN FOR THE VERY FIRST TIME. 519 00:32:58,744 --> 00:33:01,044 LET'S GO, BOAT. 520 00:33:02,214 --> 00:33:04,514 Narrator: OVER THE NEXT THREE DAYS AND NIGHTS, 521 00:33:04,516 --> 00:33:06,683 THEY WILL PUT ALL ITS SYSTEMS THROUGH A SUCCESSION 522 00:33:06,685 --> 00:33:09,753 OF GRUELING TESTS CALLED SEA TRIALS 523 00:33:09,755 --> 00:33:14,291 TO PROVE THAT THE SHIP IS SAFE TO CARRY OVER 5,000 PASSENGERS. 524 00:33:14,293 --> 00:33:16,226 [ INDISTINCT TALKING ] 525 00:33:16,228 --> 00:33:18,228 [ RADIO CHATTER ] 526 00:33:18,230 --> 00:33:19,596 THIS IS THE MOMENT 527 00:33:19,598 --> 00:33:23,300 THAT EVERYBODY HAS BEEN WORKING TOWARDS. 528 00:33:23,302 --> 00:33:26,336 IT'S MAKE OR BREAK FOR GAETANO'S TEAM. 529 00:33:26,338 --> 00:33:31,008 ♪♪ 530 00:33:51,897 --> 00:33:54,464 THE MAN MERAVIGLIA MUST IMPRESS 531 00:33:54,466 --> 00:33:57,834 IS LEAD INSPECTOR JEAN-LUC KERNEUR. 532 00:34:01,673 --> 00:34:05,742 ♪♪ 533 00:34:16,688 --> 00:34:20,290 ♪♪ 534 00:34:20,292 --> 00:34:22,893 THE TEAM PUSHES THE VESSEL TO ITS VERY LIMIT 535 00:34:22,895 --> 00:34:25,062 OVER THE NEXT 72 HOURS. 536 00:34:27,099 --> 00:34:29,666 THEY TEST ITS FIRE-SAFETY EQUIPMENT. 537 00:34:33,338 --> 00:34:37,040 THEY ASSESS HOW EASILY EMERGENCY CREWS CAN REACH A HELICOPTER... 538 00:34:40,245 --> 00:34:42,479 ...AND HOW QUICKLY THE ANCHOR DEPLOYS. 539 00:34:51,323 --> 00:34:55,025 ONE OF THE MOST CRITICAL TESTS INVOLVES THE SHIP'S PROPELLER. 540 00:34:55,027 --> 00:34:57,461 IT MUST CREATE NO NOISE OR VIBRATION 541 00:34:57,463 --> 00:34:59,996 THAT COULD RUIN THE PASSENGERS' CRUISE. 542 00:35:15,581 --> 00:35:17,781 WHILE THE SHIP SAILS AT FULL SPEED, 543 00:35:17,783 --> 00:35:20,450 THE TEAM WORKS THEIR WAY FROM DECK TO DECK 544 00:35:20,452 --> 00:35:22,486 LISTENING FOR EXCESSIVE LEVELS. 545 00:35:24,790 --> 00:35:27,524 FINALLY, THEY TEST THE GIANT AZIPODS 546 00:35:27,526 --> 00:35:30,360 THAT BOTH PROPEL AND STEER THE VESSEL. 547 00:35:44,143 --> 00:35:47,577 THE CREW WILL PUSH THE GIANT PODS BEYOND THEIR LIMITS 548 00:35:47,579 --> 00:35:52,549 BEFORE UNDERTAKING A CRITICAL CRASH-STOP TEST. 549 00:35:52,551 --> 00:35:56,920 GENTLEMEN, WE ARE GOING TO DO CRASH-STOP TEST. 550 00:35:56,922 --> 00:35:59,723 Narrator: A CRASH STOP INVOLVES USING THE AZIPODS 551 00:35:59,725 --> 00:36:01,758 TO BRING THE SHIP TO A COMPLETE HALT 552 00:36:01,760 --> 00:36:05,562 FROM A SPEED OF 21 KNOTS AS QUICKLY AS POSSIBLE. 553 00:36:08,133 --> 00:36:09,699 [ BEEPING ] 554 00:36:11,336 --> 00:36:14,171 THIS MANEUVER COULD BE CRUCIAL IN AN EMERGENCY, 555 00:36:14,173 --> 00:36:17,607 LIKE AVOIDING A COLLISION. 556 00:36:17,609 --> 00:36:22,045 SHIP SPEED LESS THAN 19, 18, 17, 557 00:36:22,047 --> 00:36:26,016 16, LESS THAN 15. 558 00:36:26,018 --> 00:36:28,852 THEY SPIN THE AZIPODS INTO FULL REVERSE. 559 00:36:28,854 --> 00:36:30,220 10 KNOTS. 560 00:36:40,399 --> 00:36:45,101 THE MAMMOTH VESSEL GRINDS TO A HALT IN 4 MINUTES 49 SECONDS, 561 00:36:45,103 --> 00:36:47,070 BUT IS THIS FAST ENOUGH? 562 00:36:58,083 --> 00:37:03,553 Narrator: AFTER A TENSE FEW DAYS AND AROUND 60 TESTS, 563 00:37:03,555 --> 00:37:08,024 THIS ADVANCE PROTOTYPE SHIP AND HER CREW RETURN TO THE SHIPYARD. 564 00:37:08,026 --> 00:37:11,695 IT'S TIME FOR INSPECTOR JEAN-LUC TO DELIVER HIS VERDICT. 565 00:37:20,639 --> 00:37:22,806 ♪♪ 566 00:37:22,808 --> 00:37:25,208 THIS IS A HUGE RELIEF FOR GAETANO. 567 00:37:36,622 --> 00:37:39,256 OVER THE NEXT NINE WEEKS, THERE'S A FRANTIC RACE 568 00:37:39,258 --> 00:37:41,424 TO FINISH INSTALLING THE PROMENADE. 569 00:37:41,426 --> 00:37:44,094 ♪♪ 570 00:37:44,096 --> 00:37:45,695 ALONGSIDE WORKERS, 571 00:37:45,697 --> 00:37:49,566 THE ENTERTAINERS PRACTICE THEIR ROUTINES. 572 00:37:49,568 --> 00:37:51,735 AND CHEFS FIRE UP THE KITCHENS 573 00:37:51,737 --> 00:37:54,638 AS THE CLOCK COUNTS DOWN TO THE MAIDEN VOYAGE. 574 00:37:54,640 --> 00:37:59,876 ♪♪ 575 00:37:59,878 --> 00:38:02,912 TWO YEARS AFTER WORK BEGAN ON ITS CONSTRUCTION, 576 00:38:02,914 --> 00:38:05,548 MERAVIGLIA LEAVES THE SHIPYARD. 577 00:38:09,855 --> 00:38:13,590 ITS DESTINATION IS THE PORT OF LE HAVRE IN NORTHERN FRANCE 578 00:38:13,592 --> 00:38:15,392 WHERE THE VESSEL WILL BE CHRISTENED 579 00:38:15,394 --> 00:38:17,327 AHEAD OF HER MAIDEN VOYAGE. 580 00:38:17,329 --> 00:38:22,098 ♪♪ 581 00:38:22,100 --> 00:38:27,537 ♪♪ 582 00:38:27,539 --> 00:38:31,074 BUT WHILE AT SEA, CREWS WORK AROUND THE CLOCK. 583 00:38:43,855 --> 00:38:49,659 IT'S TIME NOW TO BE SURE THAT THE SHIP WORKS AND WORKS WELL. 584 00:38:49,661 --> 00:38:52,696 Narrator: IT'S A SCRAMBLE TO COMPLETE THE FINISHING TOUCHES 585 00:38:52,698 --> 00:38:55,131 AS THE SHIP CLOSES IN ON LE HAVRE. 586 00:39:02,674 --> 00:39:04,841 AT LE HAVRE PORT, AN EVENTS TEAM 587 00:39:04,843 --> 00:39:07,377 PREPARES FOR THE VESSEL'S GRAND ARRIVAL. 588 00:39:09,214 --> 00:39:13,983 ♪♪ 589 00:39:13,985 --> 00:39:19,456 ♪♪ 590 00:39:19,458 --> 00:39:23,526 TODAY'S THE DAY THE SHIP HAS REACHED LE HAVRE. 591 00:39:23,528 --> 00:39:25,328 EVERYTHING IS FINALIZED. 592 00:39:25,330 --> 00:39:28,064 ALL THE TOUCHUPS HAVE BEEN COMPLETED. 593 00:39:28,066 --> 00:39:31,301 WE ARE VERY, VERY EXCITED FOR THIS EVENT, 594 00:39:31,303 --> 00:39:36,740 BUT THE SHIP IS READY, WE ARE READY, AND LET'S GO. 595 00:39:36,742 --> 00:39:42,645 AS THE SUN BEGINS TO SET, THE STARS COME OUT. 596 00:39:42,647 --> 00:39:45,048 CELEBRITIES, V.I.P.s, 597 00:39:45,050 --> 00:39:47,751 AND EXECUTIVE CHAIRMAN PIERFRANCESCO VAGO 598 00:39:47,753 --> 00:39:50,754 GATHER TO WELCOME THE SHIP. 599 00:39:50,756 --> 00:39:55,191 Vago: LADIES AND GENTLEMEN, I WOULD LIKE TO THANK THE YARDS. 600 00:39:55,193 --> 00:39:56,559 THEY'VE DONE AN AMAZING JOB 601 00:39:56,561 --> 00:40:00,063 CREATING THE MOST INNOVATIVE CRUISE SHIP TODAY. 602 00:40:00,065 --> 00:40:03,433 PLEASE JOIN ME TO GIVING A BIG ROUND OF APPLAUSE 603 00:40:03,435 --> 00:40:05,869 FOR ALL OF THE WORKERS AND ALL OF THEM. 604 00:40:05,871 --> 00:40:06,970 THANK YOU. 605 00:40:06,972 --> 00:40:09,706 [ APPLAUSE ] 606 00:40:11,576 --> 00:40:13,376 Narrator: IN A TIME-HONORED TRADITION, 607 00:40:13,378 --> 00:40:16,045 THE SHIP WILL BE CHRISTENED BY A GODMOTHER. 608 00:40:16,047 --> 00:40:19,749 TONIGHT, ACTRESS SOPHIA LOREN WILL CUT THE RIBBON. 609 00:40:19,751 --> 00:40:22,018 [ APPLAUSE ] 610 00:40:37,869 --> 00:40:38,868 [ APPLAUSE ] 611 00:40:38,870 --> 00:40:40,336 THANK YOU. MERCI. 612 00:40:40,338 --> 00:40:41,805 Vago: ARE YOU READY? 613 00:40:41,807 --> 00:40:46,476 5...4...3... 614 00:40:46,478 --> 00:40:50,280 2...1. 615 00:40:50,282 --> 00:40:52,315 GO! 616 00:40:52,317 --> 00:40:55,618 [ CHEERS AND APPLAUSE ] 617 00:40:58,657 --> 00:41:01,024 Narrator: IT'S TAKEN 3,000 PEOPLE 618 00:41:01,026 --> 00:41:03,726 MORE THAN 9 MILLION HOURS OF HARD WORK 619 00:41:03,728 --> 00:41:05,662 TO COMPLETE THE FIRST VESSEL 620 00:41:05,664 --> 00:41:09,065 IN A BRAND-NEW CLASS OF GIANT CRUISE SHIPS. 621 00:41:09,067 --> 00:41:12,068 ♪♪ 622 00:41:12,070 --> 00:41:14,471 Maresca: FINALLY, THE SHIP IS READY, IT'S LOOKING GREAT, 623 00:41:14,473 --> 00:41:18,107 AND I'M VERY HAPPY THAT OUR WORK PRODUCED THIS. 624 00:41:18,109 --> 00:41:21,411 I'M VERY, VERY HAPPY. 625 00:41:21,413 --> 00:41:27,317 ALL OUR TEAM ARE WORKING VERY, VERY HARD THESE TWO YEARS. 626 00:41:27,319 --> 00:41:31,020 SO, WE ARE VERY PROUD AND THIS CRUISE SHIP 627 00:41:31,022 --> 00:41:34,090 HAS BEEN A VERY BIG CHALLENGE, 628 00:41:34,092 --> 00:41:37,894 BUT IT'S IMPORTANT THAT THE RESULT IS GOOD. 629 00:41:40,832 --> 00:41:43,933 Narrator: THE FOLLOWING MORNING, THE FIRST PASSENGERS BOARD, 630 00:41:43,935 --> 00:41:46,536 AND THE SHIP SETS SAIL ON HER MAIDEN VOYAGE 631 00:41:46,538 --> 00:41:48,571 AROUND THE MEDITERRANEAN SEA. 632 00:41:48,573 --> 00:41:53,109 ♪♪ 633 00:41:53,111 --> 00:41:55,812 AND THE TEAM IS CERTAIN THE BILLION-DOLLAR INVESTMENT 634 00:41:55,814 --> 00:41:59,415 TO BUILD THIS GIANT WILL PAY OFF. 635 00:42:01,720 --> 00:42:01,784 AND THE TEAM IS CERTAIN THE BILLION-DOLLAR INVESTMENT