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[narrator]
In the UK,
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engineers aretaking on a seemingly
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impossible challenge.
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It'll be a massive feat
of engineering.
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They're constructinga billion-dollar stadium
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on water.
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It's probably not the best
place to build anything,
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let alone a stadium.
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This flat-pack designwill rise in record time.
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Built from pieces madeall over the country
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to hit a deadlineset in stone.
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[Colin] We're playing
Premier League football.
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We can't afford to miss it.
We have to hit that date.
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The team needs to build ina bomb-strewn site...
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[rumbling]
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Drilling a pile through
something like that would be
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game over, really.
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...dodge fragilehistoric structures
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and battle wildwaterfront winds.
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-[radio beeps]
-[worker] Keep going,
keep going, keep going.
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You're so close.
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[Alex]
The last thing we want is
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falling bolts or falling plates.
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This incredible stadium
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ranks in a league of ambitiousnew engineering wonders
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that are bigger, faster,taller, and more advanced
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than anything everconstructed before.
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This is the inside storyof the extraordinary challenge
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of building these giants.
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Liverpool, England.
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This city is famous worldwidefor two things...
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[screaming]
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...it's the hometownof The Beatles.
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And the city's half a millioninhabitants are football crazy.
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Everton is the city's oldestfootball club.
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The team's stadium,Goodison Park, is a short walk
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from Liverpool's famousRiver Mersey.
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In 1892, Goodison became
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the first custom-built footballstadium in the country.
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The thousands of workersfrom the bustling docks were
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the first supportersto pack the stands here.
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And establish a loyal fan basethat's remained strong
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for over 130 years.
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Alix Waldron worksfor the club,
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and she comes froma family of Everton fans.
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The Park End, row FF, is
the seats where I've been
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coming for years and years
with my family.
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I essentially grew up here,
coming sort of week in,
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week out with my dad
and my uncles,
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my brother when he was born,
and, you know,
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it holds so many
special memories
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and, you know, that family unit
that it feels like here.
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Goodison Park is preciousto the 39,000 fans
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that come to every game.
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But the old groundis worn and run-down.
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There are another 34,000 peopleon a waiting list for tickets.
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Everton Football Club'ssolution is to build
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an ambitious brand-new stadium
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that boosts capacityby a third.
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The club has turnedto world-renowned architect
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and stadium expert
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Dan Meis.
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He's designed ground-breakingsports arenas
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from America to Japan.
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When I first met with the club,
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the brief actually
was very clear.
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Build a modern
football stadium,
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but keep that intensity
of Goodison.
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This is Dan'srevolutionary design.
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This spectacular venue will
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seat more than 52,000roaring fans
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in the UK's steepest terracesto create a wall of sound.
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Above the stands, 4,400 tonsof structural steel support
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a 300,000 square-foot roofcapping this sporting cauldron.
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Around the outside,
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sweeping aluminum cladding
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sits abovean imposing brick facade
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that blends traditionalwith modern
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to reflect its historicLiverpool home.
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Finding a site for a newstadium in Liverpool
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is a big challenge.
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The city is crowded.
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There are few areas ripefor redevelopment close
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to Everton's spiritual homeby the Liverpool docks.
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Historically, a lot
of the, you know,
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the people who work down
on the dockyards,
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they tend -- you know,
they'd be football fans,
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they'd be going
to Everton matches,
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they'd be leaving work here
and walking up to Goodison Park
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to support the team.
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Club director Colin Chonghas led the search
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for the club's new homefor three years.
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He and the team have secureda 21-acre riverside plot
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called Bramley-Moore Dock.
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For a project
as big as a stadium,
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there weren't really
that many sites.
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We kept coming back
to Bramley-Moore Dock.
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Unfortunately, the dock
was predominantly water.
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Bramley-Moore Dock has been outof use for 40 years.
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It's roughly stadium-sized,
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but it's submerged under26 feet of water.
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When I had a conversation
with the old chairman,
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bless his soul, I did explain
to him that where we chose to
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build the stadium was probably
not the best place to build
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anything, let alone a stadium.
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The team faces a minefieldof engineering challenges.
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The dock is enclosedby 170-year-old stone walls.
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A thick bed of soft siltsits below the water.
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The perimeter is dotted withfragile original dock features
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and an historic brick tower
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that are all protectedby preservation orders.
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It's probably the worst site
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that we could have
picked to build on
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but it'll be
a real unique design.
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It's a massive feat
of engineering
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to look at
how do we do this?
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The first challenge the teamfaces is how to turn
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this water-filled site
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into a solid foundation.
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This is how they'll solve it.
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First, a boat combs the dockto remove debris.
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Next, the team fills the dock
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with nearly 16 million cubicfeet of sand.
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Compactors pound the sand60 times per minute
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with 10-ton hammers.
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Then, piling rigs use augerswith hollow shafts
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to bore holes 52 feet downto bedrock.
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The rig operators injectconcrete as the augers retract
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to prevent the bore holesfrom collapsing.
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Finally, workers push steelreinforcement cages
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into the wet concretebefore it sets
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to create a forestof foundation piles
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for the team to build on.
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August, 2021.
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The stadium team beginsraking the bottom of the dock
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to clear awayany unwanted debris
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and makes a veryunwelcome discovery.
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[Alix] We have found a couple
of ordnance devices.
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A bomb.
Yeah.
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Divers identifya total of 12 unexploded
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anti-aircraft rounds.
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The German Air Force droppedthousands of tons of bombs
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on Liverpool in World War II.
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Some of the bombsand anti-aircraft shells
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failed to detonate,
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and they are trappedin the dock's silt.
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It's a real dangerthat a machine on site
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could disturb oneof these unexploded munitions.
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The team evacuatesthe dock area.
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Drilling a pile through
something like that would be
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game over, really, so it has
to happen to make sure that,
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you know, it's safe for people
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to carry on
with the next phases.
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Engineers in Liverpool, England
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are building a brand-newsuper stadium
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for the Everton Football Club.
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An explosive ordnance disposalunit removes the larger devices
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to be dismantled off-site
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and explodesthe smaller devices
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next to the dock.
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With the danger now handled,
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the engineersrestart their work.
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They need to emptythe dock of water.
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But simply draining it willallow the massive weight
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of the River Mersey to collapsethe 170-year-old dock wall,
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turning the dockinto part of the river.
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To solve this problem,the engineers devise
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an ingenious solution.
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They bring ina special dredger.
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It scoops up hundredsof tons of sand from
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the mouth of the River Mersey.
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The dredger mixes the sand withriver water to make a slurry.
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It pumps this alonga reinforced pipe
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directly into the dock.
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The sand in the slurry sinksto the bottom of the dock
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and displaces the water.
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Pumps then drainthis water into the river.
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The dock itself is never
empty at any stage.
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And then, eventually,
the water will be
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completely removed and the sand
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becomes a solid mass
of material.
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After eight weeks of pumping,a giant expanse of sand
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emerges from the water.
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Two weeks later, the dock isalmost completely full.
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Giant compactors hammer downthe 43,000 square feet of sand.
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This makes the docksolid enough
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to start foundation piling.
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Pile driversbegin drilling down
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to the compacted sandand into bedrock.
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The hollow drills fillthe 24-inch-wide holes
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with concrete as they pull upand out of the ground.
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Crane teams then insert cagesmade from steel
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to reinforce the concrete.
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[worker] Hey, hey, hey, hey!
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Seven monthsand 2,700 piles later,
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the stadium teamhas a solid base to build on.
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[worker] Keep going,
keep going, keep going.
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Now beginsthe task of constructing
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the stadium'sconcrete skeleton.
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[worker] Hold off that.
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There's another one in.
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It takes the team 10 monthsto turn a water-filled dock
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into a dryand stable foundation.
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The next challenge is to buildthe concrete walls,
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floor, and stairsof the stadium.
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Now that the crewsare working above ground,
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they needto factor in the wind.
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It's one of the windiest places
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and one of the windiest
cities in the UK.
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So the weather conditions that
we're exposed to here
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call for a different way,
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different methodology
of building.
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Add to that a deadlineof three years
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to complete the project,
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the team needs a faster wayto build with concrete.
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The solution is to buildthe stadium in parts
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in a workshopand ship these to the site.
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[Colin]
Whilst we're actually filling
the dock in, carrying out some
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of the piled foundations
and some of the existing
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hardscape, we're manufacturing
product off-site.
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So as soon as
those foundations are ready
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to receive a wall,
the wall will be in.
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This huge factory,100 miles away in Worksop,
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has the task of manufacturingthe 30,000 tons of concrete
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components that formthe Everton Stadium.
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400 workers operate giant rigsthat produce building
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components in hoursinstead of days.
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The computer-controlledmachines pour concrete
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into a flat mold.
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And once it's dry, turn it over
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and place it into another mold.
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This produces pristine-lookingsections of wall that require
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no extra finishingwhen they get to the site.
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Everything made insidethe factory must fit perfectly.
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When a component leavesthe assembly line,
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there will be no chancefor any adjustments.
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The team's solution is to giveeveryone access
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to a 3D computer modelof the stadium.
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There are no paper plans.
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The stadium's model directlylinks with the automated
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assembly linesat sites like this one.
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Architect Jon-Scott Kohli
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runs a digital versionof the build process.
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This is a master plan for allcrews working on the project.
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Spending the time of thinking
through all of the problems
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and, you know, building a sort
of a 3D model a bit like this,
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where process of getting
information to the right people
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at the right time
so that you can go fast.
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At the build site,the workers take delivery of
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the first batch of concretepanels to make the core
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structures at each cornerof the stadium.
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The panels arrive on the backof a low-loader.
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Workers use a mobile craneto lift each panel
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to the installation site.
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-[radio beeps]
[worker] Hold her there.
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The crane operator carefullyinstalls the panels.
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00:15:08,734 --> 00:15:10,000
[worker speaks indistinctly]
258
00:15:10,901 --> 00:15:13,701
So that the steel attachesto the foundation's threads.
259
00:15:21,267 --> 00:15:25,067
Workers then fill the voidinside 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 processat 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 aresome 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 partof the stadium structure.
270
00:16:00,501 --> 00:16:04,067
They must be large enoughand 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 wayto and from their seats.
273
00:16:10,267 --> 00:16:13,868
This is a major testof the pre-built method.
274
00:16:14,033 --> 00:16:17,801
The stairs span multiple levelsand 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 raisethe 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 intothe open building,
287
00:16:48,067 --> 00:16:50,400
it must slot betweenthe existing walls
288
00:16:50,567 --> 00:16:53,300
and floor edgeswithout 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 holesmust 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 arebuilding 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 raisethe 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 holesmust 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 craneties 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 afterfinishing the foundations,
308
00:17:57,334 --> 00:17:59,501
the multi-levelstructure 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 blocksmark out the scale of the site.
311
00:18:10,067 --> 00:18:13,267
Now the engineers mustbuild 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 facilityin Worksop
314
00:18:18,934 --> 00:18:20,467
is producinga 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 teammust 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 largesteel beams,
324
00:18:47,267 --> 00:18:50,667
and crane teams lift themto 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 swinginto action.
331
00:19:10,267 --> 00:19:13,367
They bolt together the hugesteel elements to assemble
332
00:19:13,534 --> 00:19:16,467
the framework that will supportthe stadium's four stands.
333
00:19:20,801 --> 00:19:24,467
Crews on the east and westsides continue to slot together
334
00:19:24,634 --> 00:19:27,767
prefabricated concreteto 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 completedthe structure's footprint.
343
00:19:51,667 --> 00:19:56,434
And this 52,000-seaterstadium is on the rise.
344
00:19:58,868 --> 00:20:02,367
Steel columns support the roofon three sides of the original
345
00:20:02,534 --> 00:20:05,367
stadium and obstructthe view of the game
346
00:20:05,534 --> 00:20:07,267
for more than halfof the spectators.
347
00:20:08,801 --> 00:20:12,567
Every seat in the new stadiumat Bramley-Moore Dock must have
348
00:20:12,734 --> 00:20:14,467
an unobstructed viewof the pitch.
349
00:20:16,501 --> 00:20:19,467
The roof covers 300,000square feet.
350
00:20:21,701 --> 00:20:24,000
It needs a hugeframework 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 spansweighs 220 tons.
359
00:20:50,868 --> 00:20:54,033
They're too largeand heavy to lift in one pass.
360
00:20:56,467 --> 00:20:59,667
So the team must use a specialtechnique 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 deliversdozens of beams and columns.
363
00:21:12,567 --> 00:21:15,801
And steelworkers boltthem into giant frames
364
00:21:15,968 --> 00:21:17,901
one third ofthe trusses' length.
365
00:21:20,367 --> 00:21:24,067
A crawler crane liftsthe first 230-foot-long section
366
00:21:25,767 --> 00:21:28,300
and lowers it onto a temporarysupport tower.
367
00:21:29,767 --> 00:21:33,000
Then, workers liftand 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 frameworkis up and connected,
370
00:21:40,267 --> 00:21:42,267
the crew lowersthe support towers,
371
00:21:43,767 --> 00:21:46,400
and the trusses finallyhold 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 preciselythe right shape.
374
00:21:59,868 --> 00:22:03,000
This huge steel fabricationplant, 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-precisestructural elements.
379
00:22:24,400 --> 00:22:28,000
It falls to design engineerAlex Heaton to supervise
380
00:22:28,167 --> 00:22:30,801
the installation of thesemassive steel structures.
381
00:22:32,400 --> 00:22:35,868
The huge size of the roof trussmeans that his team must
382
00:22:36,033 --> 00:22:39,100
send it to the siteone piece at a time.
383
00:22:39,267 --> 00:22:42,267
Alex will spend the next eightmonths at the stadium site
384
00:22:42,434 --> 00:22:44,767
to oversee and coordinateevery 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 deliverthe 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 teamassembles them.
394
00:23:13,167 --> 00:23:16,267
The sections are so enormousthat 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 angleof 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 eyeon the weather forecast.
409
00:23:55,000 --> 00:23:58,701
A wind speed above 23 feet persecond could make the truss
410
00:23:58,868 --> 00:24:01,400
swing dangerouslyduring 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 firstcalm day arrives,
416
00:24:15,934 --> 00:24:17,567
the crawler cranemakes the lift,
417
00:24:18,767 --> 00:24:22,400
and workers with guide ropescarefully 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 inplace, 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 completethe roof's support structure.
425
00:24:51,667 --> 00:24:54,100
Alex and the steel teaminch 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 ownweight for the first time.
428
00:25:00,634 --> 00:25:02,801
And because the teamoverestimated 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 isvisible for the first time.
437
00:25:23,167 --> 00:25:25,767
Now the team needsto turn this skeleton
438
00:25:25,934 --> 00:25:28,367
into a fully-fledgedsports 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 stadiumfor the Everton Football Club.
441
00:25:48,100 --> 00:25:51,367
Architect Dan Meis designsthe new arena to blend with
442
00:25:51,534 --> 00:25:54,000
the industrial heritage ofthe surrounding structures,
443
00:25:56,100 --> 00:25:57,667
like the famousTitanic 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 stadiumin 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 presentsa 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 armyof bricklayers months
454
00:26:29,567 --> 00:26:33,067
to lay 243 courses of bricksin 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 shortstretches to create the narrow,
457
00:26:39,934 --> 00:26:41,667
perfectly straight piersby 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 wayto lay real bricks,
460
00:26:48,667 --> 00:26:50,968
but with machine-likeaccuracy and speed.
461
00:26:53,167 --> 00:26:55,267
Their off-site constructionfactory 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 intohalf 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 profilecut into its back.
466
00:27:11,467 --> 00:27:13,801
The factory team followsa 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 machineryplaces 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 moldwith 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 panelsexactly when needed,
474
00:27:35,767 --> 00:27:38,667
and crane crews bolt them intoplace
475
00:27:38,834 --> 00:27:41,767
to cover the stadium facadein a fraction of the time
476
00:27:41,934 --> 00:27:43,767
compared totraditional 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 cavernousfacility to placing
479
00:27:57,367 --> 00:27:58,968
crate after crateof brick slips.
480
00:28:04,167 --> 00:28:07,267
The key profile on the backof the bricks bonds with
481
00:28:07,434 --> 00:28:11,367
the concrete that automatedhoppers pour into each mold.
482
00:28:18,701 --> 00:28:22,000
The first brick panelsbegin arriving on site,
483
00:28:22,167 --> 00:28:24,767
millimeter-accurate and readyfor 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 handlethe panels with care.
490
00:28:44,100 --> 00:28:47,167
The shallow brick slips aremore fragile than concrete.
491
00:28:48,801 --> 00:28:51,400
One knock could cause enoughdamage 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 replacementwill 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 allowthe 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 hookscan 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 justtwo-and-a-half hours to install
500
00:29:26,067 --> 00:29:28,300
the first panels afterthey arrive on site.
501
00:29:33,367 --> 00:29:36,100
Every panel the crew fixes tothe outside of the structure
502
00:29:38,400 --> 00:29:41,000
makes the stadium look morelike 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 overthe 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 offreestanding 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 likethis cover gaps and allow
514
00:30:18,267 --> 00:30:20,801
the different sectionsto 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 allowa 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 panelsto 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 istaking 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 echoesthe 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 focuson 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 arebuilding 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 wantto 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 tomake 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 riseof 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 terracesfrom thousands of differently
557
00:32:45,734 --> 00:32:48,167
sized prefabricatedconcrete components.
558
00:32:54,167 --> 00:32:57,534
They must install each oneinto 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 team12 months to complete.
561
00:33:08,501 --> 00:33:13,000
Next, an army of seat fittersdescends on the stands
562
00:33:13,167 --> 00:33:16,367
and installs the stadium's52,000 seats.
563
00:33:27,767 --> 00:33:30,467
The steep, curved standsand the seating close to
564
00:33:30,634 --> 00:33:34,100
the pitch is a key step tocreating 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 maintainits 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 roofas a giant curve that reflects
583
00:34:30,334 --> 00:34:33,534
the sounds the fans makeback onto the stands.
584
00:34:36,000 --> 00:34:40,567
The design consistsof 872 perforated panels
585
00:34:40,734 --> 00:34:42,567
that vary in angleacross 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 longsteel beam
590
00:35:02,234 --> 00:35:06,501
with a posable hydraulic mountthat 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 toits 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 allowsthe 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 slotthe 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 ofcladding arrive on site
601
00:35:46,033 --> 00:35:49,100
just 18 months beforethe first game of the season.
602
00:35:53,567 --> 00:35:56,601
Each large panel weighs550 pounds.
603
00:35:57,868 --> 00:36:00,567
Their flat shape makes themdifficult to control
604
00:36:00,734 --> 00:36:03,334
in the strong windsthat 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 attachesthe first panel,
610
00:36:25,000 --> 00:36:26,667
and adjusts it tothe 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 towardsthe stadium roof.
613
00:36:42,367 --> 00:36:45,000
Crane slingershold 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 panelinto 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 panelsinto 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 challengejust one year
620
00:37:09,934 --> 00:37:12,901
before the stadium'sfirst 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 aluminumwrap around the stadium,
623
00:37:20,000 --> 00:37:23,767
ready to create the cauldronof 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 areracing to complete a brand-new
626
00:37:39,567 --> 00:37:42,567
soccer stadium in time forthe 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 hosttwo games a week.
629
00:37:55,000 --> 00:37:57,868
A 90-minute soccer matchinflicts 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 pitchrecovers 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 groundsmanJon 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 sitbetween 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 challengefor 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 feetof playing surface.
644
00:38:51,667 --> 00:38:54,200
Every stitch must bein the right place,
645
00:38:54,367 --> 00:38:56,000
because a gapcreates weak points.
646
00:38:59,701 --> 00:39:03,567
The solution is a giant mobilestitching rig.
647
00:39:06,000 --> 00:39:10,167
This machine unspools over37,000 miles of the plastic
648
00:39:10,334 --> 00:39:13,100
fiber and punches rowsof 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 isstitched the entire surface,
651
00:39:23,868 --> 00:39:26,400
the organic grass growsthrough the fibers.
652
00:39:28,067 --> 00:39:31,701
And John has a feel that looksand feels real, but is strong
653
00:39:31,868 --> 00:39:33,467
enough to withstandthe 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 needslight, 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 plentyof 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 orientationof 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 pitchin the shade
667
00:40:11,834 --> 00:40:14,667
and several degrees cooler thanthe north end.
668
00:40:14,834 --> 00:40:17,100
This slows grassgrowth 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 edgeof the stadium roof.
674
00:40:37,801 --> 00:40:41,767
The electricity they generatepowers 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 lampsto ensure every area of
681
00:41:02,634 --> 00:41:05,501
the pitch gets preciselythe heat and light it needs.
682
00:41:06,968 --> 00:41:09,901
So the grass grows thickand 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 dockinto a solid foundation.
685
00:41:20,634 --> 00:41:24,601
Built upwards with brick atbreakneck speed and engineered
686
00:41:24,767 --> 00:41:27,868
steel to create the ultimatematch 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 willcall home.
689
00:41:37,067 --> 00:41:39,767
It is a legacy to the teamthat made it.
690
00:41:41,501 --> 00:41:44,167
The stands finally beginto 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 beginsan 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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