Original subtitles

[Narrator] Construction, heavy machinery,

tight schedules, millions at stake.

What could go wrong?

Everything.

Whether it's faulty equipment, poor design,

human error, or just bad luck,

these are Construction Fails.

In this episode, a tale of two buildings,

including one soft story,

and many broken promises.

Is it actually possible to build

an earthquake-proof building?

At ports around the world,

a perfectly choreographed partnership is formed.

But when one dance partner has two left feet...

watch out!

Factory inferno.

How the everyday battery can turn into a miniature bomb.

To repair or not to repair?

That is the question.

Well, it's water under the bridge now.

The Sydney Opera House.

Those iconic shells.

Innovative design.

A construction fiasco.

And a world record budget buster.

When the Earth shakes, buildings fall.

Earthquakes attack the bones of structures.

It's a small wonder engineers have been working to perfect

an earthquake-proof building.

They're trying...

with mixed results.

Earthquakes are destructive forces,

causing death and devastation.

Millions of lives.

Billions in infrastructure damage.

Like the earthquake that hit Turkey in 2023.

[siren]

Turkey sits on one of the world's

most active earthquake zones: the Anatolian Plate.

When the tectonic plates

bump up against each other,

it creates friction.

And there's only so much friction that can build up

before the pressure needs to go somewhere.

When that pressure releases,

the ground moves in unexpected ways.

The 2023 earthquake killed over 55,000 people

and millions more were displaced.

[alarm]

280,000 buildings were destroyed or severely damaged.

One of those buildings was this one: the Asur.

A high-end apartment building

in the city of Malatya.

Residents were promised the building was earthquake safe.

The structure was erected

according to modernized seismic building codes.

But in this case, promises made were not promises kept.

How is it possible to safeguard above ground

against what is happening below ground?

Earthquake-resistant structures are designed to take on damage,

but not buckle.

But they're not called earthquake-proof.

When the ground moves, these buildings move with it

by incorporating into the design

a concept called ductility.

A ductile building uses materials like steel

or reinforced concrete that can absorb energy and vibrations.

Like a worn-out boxer after a few rounds,

these structures keep standing,

providing precious time for people to escape.

In earthquake-prone areas, engineers are devising new ways

for buildings to withstand seismic events.

Like the Anatolian Plate,

another extremely active geological area

is the Pacific Ocean's Ring of Fire,

the world's deadliest earthquake zone.

It's the perfect environment

to put some of these earthquake-proof

and resistant buildings to the test.

In Japan, the focus is on

constructing malleable buildings.

Something like the shocks on a car.

And if shocks on a car make the ride smoother,

why not put shocks on a building?

That's what they did with the Skytree Tower in Tokyo,

the tallest free-standing tower in the world.

The Skytree Tower stands a better chance

of staying standing,

thanks to seismic isolation.

A process where structural columns sit on rubber pads

and absorb earthquake energy.

To ensure the Skytree continues to tower above Tokyo,

a central pillar in the foundation

is attached to seismic dampers

that can absorb the energy of an earthquake.

Some buildings go even further

with the goal to emerge from a seismic event undamaged.

Continuing along the fault lines of the Ring of Fire,

Taiwan has had its share of devastating earthquakes.

Taipei 101 is a marvel of modern engineering.

It's had earthquakes and typhoons thrown at it.

Nestled between the 88th and 92nd floors

is a 660-ton steel sphere.

Like a pendulum, it sways back and forth

to counter any movement of the building

to limit seismic vibrations.

This helps the Taipei 101 remain

one of the world champions of earthquake-resistant buildings.

Back in Turkey,

the Asur apartment complex was only three years old.

It was allegedly built

according to the latest seismic codes.

Residents even paid twice the going rate for rent.

According to the developer,

whether it was the concrete or steel bars,

all materials were of the best caliber.

And yet...

Friction.

Mounting pressure.

When it releases, it unleashes energy

that amounts to almost 8 million tons of TNT.

The first earthquake lasted only 85 seconds.

The series of quakes that followed combined to make it

Turkey's deadliest in the last 100 years.

Nobody died in the Asur building collapse,

but 231 miles away, it was a different story.

The Renaissance Residence opened its doors in 2013.

The luxurious apartment complex had 249 units

and promoted itself as a piece of paradise.

Some residents claimed they were promised

it would not fall.

Others were told it had a Japanese anti-shock system

to make the foundations earthquake-proof.

The Renaissance didn't stand a chance.

And unfortunately, neither did the residents.

The Renaissance collapsed, killing more than 300 people.

In the days that followed, some were pulled from the rubble.

But too many didn't make it.

So, what went wrong?

The collapse of the Asur and the Renaissance have a story

in common: a soft one and a weak one.

The Renaissance Residence likely had something called

a soft story ground floor design.

To make room for communal areas,

this lower level had fewer masonry blocks,

putting the upper floors in danger.

This led the building to sway.

And that's not all.

The building also fell prey to a phenomenon

known as overturning, which pushes force downwards.

And this force becomes too much for the ground floor columns.

A soft story failure.

The Renaissance had a few other problems.

The building toppled southward,

indicating that the structural components

holding the whole thing together were uneven.

The cores, strong concrete walls,

were only built into the north side of the building.

Combine this with a long and thin shape,

and the risk of a collapse is built into the foundation.

Engineers who analyzed the Asur apartment collapse

believe the ground floor was a weak story

and could not hold the seismic forces hitting the building.

There is allegedly one more contributing factor

to these collapses: the human factor.

At the turn of the century, the Turkish government promised

new building standards

and plans to strengthen existing structures.

But with exploding growth, fraud, corruption,

and wrongdoing, these promises

of earthquake readiness improvements crumbled.

Mere weeks after the earthquake,

the Turkish Justice Ministry made dozens of arrests

linked to the building collapse.

On shipping docks across the world,

a delicate and dangerous dance happens

between two unlikely partners.

♪ ♪

Shipping containers are an essential link

in the international supply chain.

From furniture to food,

clothing, electronics.

They get everything and anything from here to there.

[horn blows]

When a ship arrives at its destination, the dance begins.

And like all professional dancers, timing is everything.

If one of the partners has two left feet,

like this cargo ship

approaching Keelung Port in Taiwan,

the other might trip and fall.

[Narrator] That giant crane that toppled over

was a type of gantry crane.

There are many types of gantry cranes.

Small ones that one person can operate

to lift an engine in a car repair shop,

or large ones to maneuver shipping containers.

A gantry is a frame or platform that spans around an area.

A gantry crane can straddle a work area

or resemble a traditional construction site crane.

An important function of a gantry crane is to lift

incredibly heavy loads

and stay standing.

The gantry crane in Taiwan was a container crane.

Mighty machines that sit perched on the edge

of massive piers and on barges.

These cranes lift and move large containers

on and off shipping vessels.

Container cranes are a type of gantry crane

that helped revolutionize how goods are moved

around the world.

From pulley systems to mighty modern cranes,

container cranes have gotten faster and more efficient,

but the modus operandi has basically stayed the same.

Move big things from one place to another.

Container cranes are different

from common construction cranes.

There are specialized components that help maneuver

intermodal containers with ease.

The largest of these cranes can have a load capacity

from a few hundred pounds to several hundred tons.

Container cranes commonly have one or two support beams.

This framework supports the boom.

Instead of a hook, there is the spreader,

like the arcade game that uses a claw to grab a toy.

Except in this case, the prize is a 10-foot,

one-ton shipping container instead of a stuffed animal.

The operator is in a cabin suspended from the trolley.

The operator locks onto the container, lifts it,

and commonly loads it onto the back of a truck.

These cranes require precision

and perfectly synced choreography.

Sometimes things fall down.

Portside cranes are another type of gantry crane.

They are important and efficient.

But it can be dangerous being so close to the water.

This crane in China had no chance against this cargo ship.

Gantry cranes can lift almost anything

if it fits within the load capacity.

Maybe this barge crane should have stuck to containers.

This cargo ship in Turkey set off a chain reaction

knocking down not just one crane, but three.

Only one lone crane survived.

The Yuzhou Qi Hang, a Chinese ship, was preparing to dock

at Pier 20 of Keelung Port in Taiwan.

The dockside container crane sat idle,

waiting to offload the incoming vessel.

The two dance partners would only briefly meet.

So, what went wrong?

It's a tale of two cranes.

In addition to the pier's portside crane,

the cargo ship was also carrying cranes.

Deck cranes are mounted on the upper deck of a ship

as an additional way of offloading.

The Yuzhou Qi Hang was traveling

at a steady two nautical miles,

and no warnings were communicated.

The deck crane collided with the container crane

on the wharf.

Container cranes are built to lift

incredibly heavy loads vertically.

But there is a vulnerability

when it comes to horizontal loads.

The container crane most likely buckled under the pressure.

There are also a few proactive ways

to avoid another catastrophe.

Location, location, location.

Cranes need to be dockside to unload ships,

but placed at a safe distance

in order to decrease the chance of collision.

And perhaps the most important element

is in the hands of the operators.

Communication is key between the people guiding the ship

and the port's harbormaster.

Both sides need to be familiar

with the positioning of the boat

and know the safe zones of the docking area.

Fortunately, no one was hurt in the accident.

But this was no fender bender,

as a new container crane can cost millions of dollars.

The crane at Keelung Port will dance again.

Hopefully, with a better partner.

Do not adjust your set.

Much of what you're about to see appears to be in reverse.

Which is to say, that going forward,

things will be moving backward.

Keep your eye on the truck.

Not that truck.

That truck.

Looks like somebody may have taken a lunch break

and forgot the hand brake.

Is this one of those new driverless vehicles?

If so, they haven't quite worked out the bugs.

Let's listen in on lesson one in tractor trailer parking.

[shouting]

[Trucker] You hit it.

[Narrator] There won't be a lesson two.

This driver's last job was brain surgery,

but he was looking for a challenge.

Think that was impressive?

Now try it with no hands.

You've heard of U-turns?

This is an O-turn.

[onlookers speaking foreign language]

This guy definitely needs a new GPS.

Listen, don't wait on dinner.

I'm stuck in traffic.

Really, really stuck.

By flooring it in reverse, this driver executes

a perfect cargo drop straight into the pit.

It's a tried and true, foolproof technique.

Well, not entirely foolproof.

This excavator comes with a neat option.

It can see into the future.

This new garbage truck is equipped

with all the latest features...

except a rearview mirror, apparently.

Just back up so Buddy has room to clear the--

Never mind.

In an attempt to work through their differences,

their nautical therapist suggested

these boats try role reversal.

So for a change, the tug got tugged.

Some people just can't take a hint.

Clearly that car's not going your way.

It's just out for a spin.

Looks like due to budgetary constraints,

this delivery service was obliged

to lay off all its delivery personnel,

except this guy.

Looks like traffic on the road is backed up.

Correction: backing up,

so this lorry can take a quick detour through the swamp.

Why don't I just drop you off here?

After this minor setback, we shouldn't jump to conclusions,

but it's fair to assume that this long-haul trucker

may want to cut his career short.

If he's so inclined, this fellow's about to learn

a few things about responsibility--and gravity.

♪ ♪

You can back into a car.

You can back into a ditch.

But you can't go back in time.

So better keep your eyes on the rearview.

Because if you don't,

you're liable to back into a reversal of fortune.

[Narrator] Lithium batteries are everywhere

and power almost everything around us.

They can be a light in the dark,

see what's on next,

wake us up in the morning,

get people from home to work,

clean the house,

and keep kids busy.

Sometimes all at once.

Some are rechargeable.

And of course,

they can create problems.

Especially when the family pet gets involved,

or when the charger overheats.

[beeping]

That's one way to get out of a speeding ticket.

They are safe... until they're not.

But sometimes the batteries don't even make it

out of the factory.

South Korea.

26 miles south of Seoul in the city of Hwaseong.

June 24, 2024, at 10:30 am,

a deadly fire was triggered by an explosion

at a battery factory.

The country is a key player in global supply chains

for major industries such as electronics,

telecommunications, and chemicals.

And they are a leading producer of lithium batteries.

Aricell is a company that makes batteries

used for things like these:

sensors and radio communication devices,

particularly for smart meters used in smart grids.

On the second floor of the Hwaseong factory,

lithium batteries exploded.

It took 15 seconds for the entire floor

to be filled with toxic smoke.

The workers didn't stand a chance.

The fire burned for five hours.

When the smoke cleared, 23 people were dead.

One of South Korea's deadliest industrial accidents

in recent years.

So, what went wrong?

A battery has three components.

Electrons flow from the anode to the cathode,

and the electrolyte surrounds these components,

allowing for the transfer of charged ions.

Metallic lithium was first added to batteries

in the 1970s.

The lightest metal, lithium provides

electrochemical ability and extended density of energy

ideal for battery production.

The lithium-ions were added in the 1990s.

These flow from the anode to the cathode,

powering the device.

They can also travel back from the cathode to the anode,

making this type of battery rechargeable.

They can become dangerous when overcharged,

short-circuited, damaged,

or if the metallic lithium comes in contact with moisture.

Any of these events can trigger

something called thermal runaway.

A game of dominoes,

but one that happens inside the battery.

If the temperature of a component rises,

it could cause a chain reaction of heat.

That heat spreads, generating more heat.

Things go boom.

Toxic fumes are released into the air, including lithium,

hydrogen chloride, and sulfur dioxide.

When ignited, they burn ferociously.

Lithium fire temperatures can quickly reach

almost 4,000 degrees Fahrenheit.

Like this fire that happened in Morris, Illinois,

on June 29, 2021.

A warehouse was storing nearly 100 tons of lithium batteries.

The firefighters in Morris learned the hard way

that water can intensify a lithium fire.

Sometimes, the way to fight a lithium fire

is to let it burn and burn.

In Morris, it took almost two weeks

before the fire was officially considered extinguished.

This battery recycling treatment facility in Scotland

also went up in flames.

The billowing smoke was so toxic,

local residents were told to remain indoors

and keep windows and doors closed.

China is also a leading producer of lithium batteries.

Where there's production,

there's also potential for accidents.

In 2021, this was the scene

at a massive battery recycling warehouse in China.

Lithium batteries exploded in a mushroom cloud of toxic smoke.

Back in Hwaseong, South Korea,

there were around 35,000 units of batteries

inside the factory.

That's a lot of power to unleash.

The building's upper level collapsed.

Large chunks of concrete were blown into the street.

The workers had a 37-second window to escape.

One or two breaths of toxic fumes

renders a person unconscious.

Adding to the disaster, the evacuation route

and safety instructions

were not properly communicated to workers.

Fire officials on site suggested that emergency exits

were covered up by boxes of batteries.

And there was no time to figure this out in the moment.

In September 2024, the Suwon District Court

approved a warrant to arrest the CEO and executive

of Aricell, a father and son duo.

South Korea's Ministry of Employment and Labor

said the CEO had been arrested

on charges of causing the deaths of 23 people.

Batteries are a powerful source of energy.

Great power demands great responsibility.

They can bring down an entire building,

but when handled with care and precision,

disasters can be avoided.

[Narrator] If there is one constant thing,

the world is always changing, evolving.

Technology is accelerating at a rapid pace.

Every time you turn around, there's a new cell phone,

an updated operating system, artificial intelligence.

Many of these radical innovations

are powered or recharged by electricity.

And how that electricity is delivered to these items

has evolved somewhat slower.

Before the common light switch, there was a knob.

And along with that knob came a tube.

Knob-and-tube wiring was one of the earliest ways

to distribute electricity throughout a building.

Knob-and-tube became common in North America from the 1880s

and was phased out in the 1940s

after being considered a safety hazard.

But let's go back to the beginning.

The first patent for knob-and-tube wiring

was filed in 1888.

This innovation led to one of the earliest ways

to cheaply and easily distribute electricity

through a home or building.

So, how does knob-and-tube wiring actually work?

This wiring system consists of copper conductors

covered with a sleeve.

These wires pass through joists and walls using ceramic tubes.

To ensure that no other part of the cable

came into contact with wood or other materials,

they were pulled tight and wrapped around ceramic knobs

fixed directly into the building infrastructure.

These knobs and tubes created an intricate web

behind the walls of a structure that suspended wires

a safe half inch away from any wood or other combustibles.

Knob-and-tube wiring is no longer installed,

but still exists in older homes.

Not bad, considering it is a technology

that is over 100 years old.

But cautionary tales come with this kind of wiring.

The U.S. Fire Administration estimates that every year

there are almost 24,000 fires

involving home electrical distribution systems.

These fires cause more than 300 deaths, about 800 injuries,

and over $1.5 billion in property loss.

They believe that older homes are the most at risk

when it comes to electrical wiring fires.

Professional electricians also sound the alarm

that knob-and-tube wiring

is an incredibly dangerous fire hazard.

So, what's the problem?

In the 1940s, Americans welcomed

shiny, new, modern appliances into their homes.

Knob-and-tube can handle modern appliances,

just not so many of them all at once.

With appliances like dishwashers,

refrigerators and ovens,

homes' electrical demands outgrew knob-and-tube.

Knob-and-tube plugs only have two receptacles

and lack the third slot.

And this is the biggie: they lack a ground wire.

Since 1962, the U.S. National Electrical Code has required

three-prong outlets for all new builds.

The ground wire provides an alternative pathway

for electricity that strays from an appliance.

Electrical outlets have a voltage limit.

If the energy that runs through it exceeds that voltage,

the risk of failure goes up.

Most houses today use about 150 amps of electricity,

compared to the knob-and-tube limit of 60 amps.

Combine the lower voltage and lack of grounding wire

with knob-and-tube outlets, and that risk is even higher.

What surrounds the wiring can also be a problem,

especially if it's covered with thermal insulation.

The ceramic knobs cannot cool

and present a major fire hazard.

Another risk is when homeowners

try to fix knob-and-tube wiring themselves.

Instead of DIY, try calling an electrician.

By the 1950s, advances in electrical delivery systems

evolved using non-metallic sheathed cables.

They're much safer and can handle larger loads.

It's not that knob-and-tube has changed,

it's that we changed.

But according to Canadian home insurance companies,

99% of houses built before 1950 have knob-and-tube wiring

present and active, even if the homeowners were not aware.

So, in North America, chances are

there is knob-and-tube wiring lurking somewhere

between the bones of your old house.

But remember, if you do find it, call a professional.

It's a well-worn cliché that we are what we do.

We spend more time on the job than with our family.

A bad day can really be a threat to our survival.

Because it's not just construction jobs

that are risky.

You never know what mayhem awaits you at the office.

In today's heady-paced workplace,

a go-getter can quickly climb the ladder of success.

But if you don't get results,

you can fall just as fast.

Even if sales were through the roof.

The marketing team returns from their breakout session,

eager to implement their new disruption strategy:

rebrand the business from the ground up.

This is what's known as a water cooler moment.

Keep your eye on Jenkins.

He's falling down on the job.

Let's face it.

He might not be warehouse material.

I'm sorry, but your contract clearly stipulates

that once terminated,

you're obliged to return the company car.

Thank you.

Looks like this applicant was not suited for a desk job.

Our new hours of operation are...

always.

That's right, sir, we can fix the glass on your cell phone,

the glass on your tablet and...

just about anything, really.

Shattering previous records,

this year's surprise growth industry is glass door repair.

Ever wonder what the CEO does all day?

This reception desk wasn't very receptive at all.

I'm sorry, sir, but Mr. Twitchum is very busy.

You'll have to make an appointment.

Oh. He can see you now.

Armbruster completes his hefty report

on inadequate office shelving.

Some people get so hung up on their work,

they simply can't get away.

These days, job security has taken on a whole new meaning.

Never mind the raise.

Forget the bonus.

What you really want out of your 9-to-5 is to survive.

[horn blaring]

[Narrator] Germany's vibrant culture

boasts intricate cathedrals, opulent castles,

bustling squares and beer halls,

and bridges.

Lots and lots of bridges to connect all these places.

The Carola Bridge was one of Dresden's busiest bridges

until it plunged into the river below

in the early hours of September 11, 2024.

Fortunately, no one was injured.

But the incident caused major traffic chaos

on the roads and waterways of the eastern German city.

The tram system was kaput.

Motorists and pedestrians, rerouted,

cargo and sightseeing vessels, brought to a halt.

To make matters worse,

all the debris from the catastrophic collapse

isn't expected to be cleared away anytime soon.

Originally built in 1895,

the bridge was a beautiful piece of architecture.

But it was destroyed during World War II,

along with most of Dresden.

When the Carola Bridge was rebuilt in the late 1960s,

a high strength material called pre-stressed concrete was used.

This type of concrete is compressed during production

to withstand more force.

It was function over flair in its new design.

Three sections made up of pre-stressed concrete

make up the 1,230-foot-long bridge,

supported by key beams that consist of girders

shaped like a hollow box,

hence the name, box girder bridge.

Box girder bridges are everywhere.

They are high-strength, durable,

and require minimal maintenance.

This design is indispensable

when it comes to long-spanning bridges.

By the 1970s, the reinvented Carola Bridge

became a workhorse for the town of Dresden,

and one of the longest spanning pre-stressed bridges

in all of Germany.

So, what went wrong?

Investigators looked into several possibilities,

including the corrosion of the bridge's steel elements,

sudden change in temperature

contributing to the level of stress on the steel

the night of the collapse,

and wire breaks within the bridge as contributing factors.

But the investigation had its setbacks.

Flooding along the River Elbe significantly slowed down

the dismantling of the bridge.

During the tear-down, samples of material were taken in

for chemical testing to help identify the cause of collapse.

Three months later, the investigation revealed

that the bridge's steel had been corroding away

since its very construction.

The corrosion occurred on the inside;

out of sight and out of mind.

Corrosion combined with wear and tear

can take a toll on an old bridge.

Along with these findings, investigators uncovered

a far larger problem--

maintenance, or lack there of.

The investigation revealed early signs of instability

in the Carola Bridge.

A satellite-based assessment revealed unusual movement

on the section of the bridge that collapsed.

The images were taken two years prior to the failure.

It's unclear whether maintenance officials

were aware of this data until after the fact.

In Germany, bridges are inspected every six years.

The stability, traffic safety, and durability are evaluated

and given a rank of one to four.

One being in very good condition,

and four being unsatisfactory.

The Carola Bridge didn't exactly

ace its last inspection.

The first section of the bridge renovated in 2021

was rated satisfactory.

The middle, renovated in 2023, sufficient.

And the third section, where the collapse occurred,

was rated unsatisfactory.

This section of the bridge was slated for renovation

in 2025, but never got there.

What's the hold up?

Carola was just one of 5,000 German bridges

in need of some TLC.

The thousands of bridges across Germany

that once facilitated smooth, cross-country travel

have aged out.

Nearly half of the autobahn bridges across Germany

were built before 1985 and are now in need of repair.

When repairs aren't done in time,

entire bridges can be rendered obsolete.

♪ ♪

The structural damage becomes irreparable

and bridges are closed down

and eventually demolished.

Thanks to the damage done by the collapse,

this is the end of the road for the Carola Bridge, too.

Investigators concluded that the rest of the bridge

could collapse just as suddenly.

The remaining sections will be demolished.

But it will be years before the bridge is replaced,

further highlighting the need for timely bridge maintenance,

and a way to prioritize the queue

for which bridges need immediate attention

before they, too, follow suit.

[Narrator] Some see seashells.

Others see sails.

Either way, the Sydney Opera House is world famous.

And in terms of construction projects, it is also infamous.

The awe-inspiring design.

The ingenious engineering.

It's iconic.

The Sydney Opera House is a UNESCO World Heritage Site.

It's one of the most photographed buildings

in the world.

Around 11 million people visit the Opera House every year.

But behind the famous facade is a story

of near construction fails and ongoing problems.

The Sydney Opera House took almost four times longer

to build than originally planned.

From untested creative designs

to the ground itself,

to that remarkable roof.

It was a long and winding road

to when Queen Elizabeth II officially opened it

on October 20, 1973.

In the 1950s, Australia's economic engine

was building steam.

After the Second World War,

the country saw massive growth in immigration from Europe.

The country wanted a world class symbol.

In 1955, Bennelong Point was declared the site

and an international design competition was held.

There were 223 entries from 28 countries.

Here's what the Sydney Opera House could have looked like.

The judges settled on Danish architect Jorn Utzon's design.

It was a bold vision that should have taken four years

but ended up taking 14.

The budget for this four-year project

was an estimated 7 million Australian dollars.

It ended up costing more.

A lot more.

So, what went wrong?

As radical as Utzon's design was,

it had no engineering consultation when submitted.

In fact, many industrial professionals

deemed it impossible to build.

Even the construction site was laden with problems.

The chosen site, Bennelong Point,

sticks out from the coast.

The engineers did not properly assess the soil

and discovered it would not provide a safe foundation.

Just to prepare for the build,

concrete was poured onto the soil

to make the site suitable for the intended weight.

The ground was now solid,

but the build was anything but smooth.

The next challenge was constructing

those iconic seashells.

Utzon insisted the roof had to maintain

the circular seashell shapes.

But his design plans were deemed structurally unsound.

And the curved surfaces were geometrically different sizes,

which would considerably add to the cost of the building.

Time was ticking.

It took Utzon four years to come up with something

called the spherical solution.

Utzon's epiphany was that even though each shell

was a different size,

they could all originate from a single, constant form,

such as the plane of a sphere.

With the use of repetitive geometry,

the shells could be prefabricated,

helping to lower the cost.

Like whether you're peeling an orange or a grapefruit,

the item might be different,

but the shape of the peel is geometrically the same.

Repetitive geometry meant the curved roof structures

were able to be built on site,

using a uniformed 246-foot diameter.

With these precast shell ribs being built

right on Bennelong Point,

it was like going from building one car at a time

to establishing the assembly line in a factory.

This sped up the process and brought down the price.

As they worked on the curved roof,

Utzon wanted a specific look for the tiling

that would cover the seashells.

Three years later, the Sydney tile was created

specifically to cover the exterior of the Opera House.

These specially made tiles were made from the same kind of clay

found in Japanese ceramic bowls.

Similar to the roof, the tiles were able to be made on site,

reducing ballooning costs.

The roof is made up of over one million tiles.

On that day in October when the Sydney Opera House

finally opened its doors,

it consisted of the 2,679-seat concert hall, opera theater,

and three other theaters of various sizes.

Over the many years and delays, the budget exploded

from the estimated 7 million Australian dollars

to the actual cost of 102 million Australian dollars.

The Guinness World Record called it "the pre-eminent

single example of a cost-planning disaster

in modern accounting history."

And the criticism doesn't stop with the exterior.

The Sydney Symphony Orchestra almost boycotted the venue

because of the terrible acoustics.

And while staging an opera,

actor John Malkovich said that the venue

"has acoustics that would do an airplane hangar a disservice."

But in 2023 alone,

the Sydney Opera House generated $1.2 billion in value

for the Australian economy.

Seems as though that $102 million

was worth every penny.