Original subtitles

Narrator: A PIONEERING TEAM OF ENGINEERS

IS ATTEMPTING TO BUILD A GIANT --

ONE OF THE BIGGEST AND MOST ADVANCED CRUISE SHIPS

IN THE WORLD.

IT'S LIKE A PUZZLE -- A BIG PUZZLE.

YOU CANNOT MAKE A MISTAKE.

Narrator: COSTING $1 BILLION, THIS GIANT SHIP

WILL CARRY MORE THAN 5,700 PASSENGERS

AND WILL HAVE THE WORLD'S LARGEST L.E.D. PANEL ON A SHIP.

FOR TWO YEARS, THE TEAM BATTLES MOUNTAINS OF METAL...

YOU HAVE TO SOLVE PROBLEM AFTER PROBLEM.

...TO PRODUCE STATE-OF-THE-ART MACHINERY.

IT'S TIME NOW THAT THE SHIP WORKS AND WORKS WELL.

Narrator: THIS COLOSSAL CRUISE LINER

RANKS IN A LEAGUE OF AMBITIOUS NEW ENGINEERING WONDERS

THAT ARE BIGGER, FASTER, TALLER,

AND MORE ADVANCED THAN ANYTHING EVER CONSTRUCTED BEFORE.

THIS IS THE INSIDE STORY OF THE EXTRAORDINARY CHALLENGE

OF BUILDING THESE GIANTS.

-- Captions by VITAC -- www.vitac.com

CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS

♪♪

IN SAINT-NAZAIRE, FRANCE, IS THE STX YARD --

ONE OF THE LARGEST SHIPYARDS ON EARTH,

AND ONE OF THE FEW CAPABLE OF BUILDING A VESSEL SO MASSIVE.

Vago: THIS SHIP WILL BE IMPOSSIBLY HUGE.

I MEAN, IN THE LAST 15 YEARS, SHIPS --

THEY'VE GROWN TREMENDOUSLY.

SO, YES, IT WILL BE BIG.

Narrator: WITH ITS AMBITIOUS SIZE AND SCALE,

THIS NEW PROTOTYPE WILL PUSH THE BOUNDARIES

OF CRUISE-SHIP DESIGN AND ENGINEERING.

SHE IS CALLED MERAVIGLIA

AND IS THE VISION OF PIERFRANCESCO VAGO.

MERAVIGLIA, I THINK, WILL REALLY TURN HEADS.

WE WANTED TO MAKE A STATEMENT.

SHE'S GONNA BE A BIG SHIP, AND WE WANT TO MAKE HER FUN.

WE WANT TO HAVE A LOT OF INNOVATION.

♪♪

Narrator: PIERFRANCESCO IS INVESTING $1 BILLION IN THIS OCEAN LINER.

♪♪

WE'RE TALKING ABOUT A LOT OF MONEY,

SO I'M CERTAINLY NOT GONNA SAVE,

YOU KNOW, ON INNOVATION, AND I WANT THE LATEST.

Narrator: BUILDING THE GIGANTIC SHIP

IS UP TO SITE MANAGER GAETANO ROLANDO.

HE MUST MAKE SURE THE MERAVIGLIA SETS SAIL ON TIME.

[ HORN HONKS ]

THIS IS A VERY EXCITING CHALLENGE FOR ME

AND FOR ALL OUR TEAM BECAUSE EVERY DAY IS DIFFERENT,

EVERY DAY IS SOMETHING NEW.

♪♪

Narrator: GAETANO HAS CONSTRUCTED SIX VESSELS

OVER THE PAST 15 YEARS,

NOTHING NEARLY AS AMBITIOUS AS THIS ONE.

♪♪

Rolando: SO, THIS IS THE BIGGEST SHIP I'VE BUILT.

I'M VERY EXCITED FOR THIS BIG CHALLENGE.

Narrator: THIS IS THE GIANT

GAETANO AND A TEAM OF 3,000 SHIPYARD WORKERS

MUST SOMEHOW BUILD.

MEASURING 1,036 FEET LONG AND 214 FEET TALL,

THIS SHIP WILL WEIGH MORE THAN 3 TIMES AS MUCH AS THE TITANIC.

ON BOARD, THEY PLAN TO BUILD 20 BARS AND RESTAURANTS,

TWO THEATERS,

AND FOUR SWIMMING POOLS WITH SLIDES

TO CATER FOR THE 5,700 PASSENGERS

STAYING IN 2,244 CABINS.

INSIDE, FOUR GIANT ENGINES WILL POWER THE SHIP,

PROPELLING TWO ROTATING 190-TON THRUSTERS.

♪♪

AT THE HEART OF THE VESSEL WILL BE

A MEDITERRANEAN-STYLE SHOPPING PROMENADE

TOPPED WITH A 262-FOOT LONG L.E.D.-SCREEN CEILING --

THE LONGEST SCREEN EVER BUILT ON A SHIP.

THE COMPANY HAS BUILT 12 CRUISE SHIPS OVER THE LAST 29 YEARS,

BUT THIS WILL BE THE LARGEST AND MOST ADVANCED LINER

THEY HAVE EVER ATTEMPTED.

♪♪

Vago: THE PRESSURE IS HUGE. THE RISK IS HUGE.

YOU KNOW, YOU KEEP A SHIP FOR 30, 50 YEARS,

YOU KNOW, YOU CAN'T MAKE A MISTAKE.

Narrator: TO FILL THE SHIP WITH PASSENGERS,

TICKETS FOR THE MAIDEN VOYAGE HAVE GONE ON SALE

BEFORE THE VESSEL IS COMPLETE, AND IT'S ALREADY SOLD OUT.

CANCELING THIS HIGH-PROFILE JOURNEY WOULD BE A DISASTER --

COSTING THE COMPANY HUNDREDS OF THOUSANDS OF DOLLARS --

SO THERE'S NO ROOM FOR DELAYS.

♪♪

THE HARDEST PART OF MY JOB IS TO DELIVER THE VESSEL ON TIME.

Narrator: WITH THE CLOCK TICKING,

GAETANO AND THE SHIPYARD HAVE JUST 26 MONTHS

TO BUILD, TEST, AND DELIVER THE MASSIVE SHIP.

EVERY DAY -- DAY BY DAY,

THE PRESSURE ON OUR SHOULDERS COMING.

CONSTRUCTING THIS PROTOTYPE VESSEL

INVOLVES A SERIES OF KEY CHALLENGES.

THIS IS THE PLAN.

THE FIRST TASK IS TO TRANSFORM 39,000 TONS OF STEEL

INTO 50 HUGE SECTIONS CALLED MEGABLOCKS.

♪♪

THESE BLOCKS WILL JOIN TOGETHER TO FORM THE SHIP'S HULL.

NEXT, WORKERS MUST BUILD AND ATTACH

TWO SPECIALLY-DESIGNED THRUSTERS CALLED AZIPODS.

THESE CARRY THE VESSELS 28-TON PROPELLERS

THAT WILL PUSH IT THROUGH THE WATER.

♪♪

ONCE AFLOAT, THE TEAM THEN NEEDS TO CONSTRUCT AND FURNISH

THE 2,244 CABINS...

♪♪

...EQUIP THE DECKS,

AND INSTALL THE 1,450 PANELS

TO CREATE THE PROMENADE'S ONE-OF-A-KIND L.E.D. CEILING.

IF THEY CAN COMPLETE THE VESSEL ON TIME,

ENGINEERS MUST THEN THOROUGHLY TEST THE SHIP

AND PUT HER THROUGH A SERIES OF GRUELING SEA TRIALS.

♪♪

GAETANO AND THE SHIPYARD START WITH 39,000 TONS OF BARE STEEL.

THEY MUST SOMEHOW TRANSFORM IT

INTO THE 50 GIANT MEGABLOCKS THAT FORM THE SHIP'S HULL.

WORKERS FEED EACH SHEET OF STEEL INTO THESE GIANT MACHINES.

THEY FIRE A 32,400-DEGREE FAHRENHEIT

JET OF SUPERHEATED GAS CALLED PLASMA THROUGH THE STEEL.

THIS CUTS THE INDIVIDUAL PIECES OF THE SHIP TO SIZE

WITH ABSOLUTE PRECISION.

THEY BUILD THE BLOCKS

FROM AROUND 300,000 INDIVIDUAL STEEL PIECES.

IT'S A GIANT JIGSAW.

WORKERS MUST SORT AND DELIVER EACH PIECE

TO THE RIGHT WORKSTATION SO IT ENDS UP IN THE CORRECT PLACE.

ANY MIXUPS COULD DELAY WORK ON THE WHOLE PROJECT.

ENGINEERS ASSEMBLE SECTIONS OF THE SHIP IN THESE WORKSHOPS.

THEY PIECE TOGETHER GIANT PANELS

THAT FORM EACH MEGABLOCK UPSIDE DOWN.

♪♪

THIS MAKES IT EASIER TO INSTALL THE SHIP'S CRUCIAL SERVICES

INTO THE CEILING --

THIS INCLUDES 932 MILES OF ELECTRICAL CABLE,

124 MILES OF VENTILATION DUCTS, AND 158 MILES OF PIPEWORK.

EACH COMPLETED PANEL MEASURES ONE DECK HIGH.

ONCE PUT TOGETHER, THE PLAN IS FOR WORKERS

TO PUT IT IN A SPECIAL FRAME TO ALLOW THE YARD'S GIANT CRANE

TO LIFT AND FLIP THE PANEL OVER --

TURNING IT THE RIGHT WAY UP.

AROUND 20 PANELS MAKE UP EACH MEGABLOCK.

THEN THE CRANE WILL LOWER EACH COMPLETED BLOCK INTO THE DRYDOCK

WHERE WORKERS CAN WELD THEM TOGETHER.

IT TAKES NEARLY 11 WEEKS TO CONSTRUCT THE BLOCKS,

BUT WITH MULTIPLE CREWS BUILDING MORE THAN ONE AT A TIME,

THIS METHOD SHOULD SPEED UP THE TIME IT TAKES

TO BUILD THE VESSEL.

♪♪

BUT IMPLEMENTING THIS PLAN IS EASIER SAID THAN DONE,

AND THERE'S ANOTHER BIG PROBLEM.

SO, THEY CALL IN THIS GIANT GANTRY CRANE

TO TURN EACH MASSIVE PANEL OVER AND ASSEMBLE THE MEGABLOCKS.

SOARING 213 FEET TALL

AND WITH A LIFTING CAPACITY OF OVER 1,500 TONS,

THIS IS ONE OF THE BIGGEST CRANES IN EUROPE.

THE CRANE OPERATOR SLOWLY RAISES THIS GIANT PANEL.

♪♪

♪♪

♪♪

♪♪

THE PANEL HANGS LIKE A HUGE AIRBORNE SAIL.

A SUDDEN GUST FROM THE ATLANTIC NOW COULD PROVE DISASTROUS.

Narrator: AT ONE OF THE BIGGEST SHIPYARDS ON EARTH,

ENGINEERS ARE BUILDING

THE GARGANTUAN MERAVIGLIA CRUISE SHIP.

BUT AS THEY LIFT THIS 100-TON PANEL,

THEY'RE ALSO BATTLING WINDS OFF THE ATLANTIC.

♪♪

[ RADIO CHATTER ]

♪♪

♪♪

DESPITE THE WINDS, THEY'RE ABLE TO LOWER THIS PANEL DOWN,

WHICH WILL FORM THE BASE OF A NEW MEGABLOCK.

EACH MEGABLOCK THEN TAKES 11 WEEKS TO BUILD.

WORKERS FIT THE BLOCKS TOGETHER TO FORM THE SHIP'S BOW,

CENTRAL HULL...

STERN...

AND THE CAPTAIN'S BRIDGE.

IT TAKES AROUND 11 MONTHS FOR THE SHIPYARD

TO PIECE ALL 50 GIANT MEGABLOCKS TOGETHER

TO FORM THE VESSEL'S CORE SKELETON.

WITH MORE THAN 8 MILES OF JOINTS TO WELD

AND 10 FOOTBALL FIELDS OF BARE METAL TO PAINT,

THE DOCK TEAM HAS THEIR WORK CUT OUT FOR THEM.

♪♪

BUT AS THE BARE SKELETON OF THE VESSEL BEGINS TO TAKE SHAPE,

ANOTHER TEAM IS GEARING UP TO START THE MONUMENTAL TASK

OF CONSTRUCTING THE INSIDE OF THE SHIP.

GIUSEPPE MARESCA IS OVERSEEING THE DAUNTING INSTALLATION

OF A STAGGERING 2,244 CABINS.

Maresca: IT'S VERY IMPORTANT FOR US TO HAVE ALL THE CABINS ON BOARD

IN THE RIGHT TIME AND FOR THE DELIVERY DATE,

OTHERWISE, WE WILL HAVE UNHAPPY GUESTS AND UNHAPPY BOSSES.

THE CABINS WILL HAVE AN ACCESS TO A BALCONY.

TO CHECK THE POSITION OF THE CABIN,

WE CAN SEE THE TRACING ON THE FLOOR.

THIS IS WHERE ONE CABIN WILL BE AND THERE ANOTHER ONE,

THERE ANOTHER ONE, THERE ANOTHER ONE.

Narrator: GIUSEPPE FACES AN ENORMOUS PROBLEM --

IT WOULD TAKE YEARS TO BUILD

AND EQUIP EACH INDIVIDUAL CABIN ON BOARD BY HAND,

AND THE SHIP WOULD NEVER MAKE THE SCHEDULE

FOR ITS MAIDEN VOYAGE.

SO ENGINEERS HAVE BEEN DEVELOPING AN INGENIOUS SOLUTION

TO THIS PROBLEM

AT THIS SPECIAL FACTORY JUST OUTSIDE THE YARD.

WELCOME TO THE CABIN FACTORY.

THIS IS WHERE WE BUILD OUR CABINS.

♪♪

EVERY 25 MINUTES WE PRODUCE ONE NEW CABIN.

THAT MEANS THAT IN ONE DAY,

WE HAVE PRODUCED ABOUT 16 CABINS PER DAY.

♪♪

INSTEAD OF BUILDING EACH CABIN

FROM THE GROUND UP ON BOARD THE SHIP,

PATRICK'S TEAM IS PRE-ASSEMBLING EACH ROOM

JUST LIKE FLAT-PACKED FURNITURE ON THIS UNIQUE ASSEMBLY LINE.

EACH UNIT STARTS LIFE WITH A WATERTIGHT BATHROOM SHELL.

WORKERS INSTALL THE ELECTRICAL WIRING,

PLUMBING, BED FRAME...

EVEN A DESK.

MERAVIGLIA HAS BEEN QUITE A BIG CHALLENGE FOR US

TO PRODUCE SUCH A LARGE QUANTITY OF CABINS

IN A SMALL PERIOD OF TIME.

WE START WITH A BASE FRAME, AND WE PUT THE WALLS AROUND.

AND THEN WE WILL DO THE ROOF ON THE TOP.

WE'LL PUT THE FURNITURE INSIDE.

I'VE NEVER HAD A SHOWER IN THIS...

BUT MY PRODUCTION MANAGER, YES,

HE HAS ALREADY TESTED THAT ON THE PRODUCTION LINE, YES.

Narrator: THEY INSTALL THE AIR CONDITIONING,

WI-FI POINTS,

AND TOUCH-SENSITIVE LIGHTING TO COMPLETE EACH CABIN UNIT.

HERE, MOST OF THE FURNITURE COMES ALREADY ASSEMBLED

EXCEPT FOR THE BIG FURNITURE THAT WE WILL ASSEMBLE OURSELVES.

AGAIN, ONE WARDROBE EVERY 25 MINUTES.

Narrator: BEFORE FINISHING, THEY NEED TO INSTALL

ONE KEY PIECE OF EQUIPMENT

TO MAKE SURE THAT THE CABINS FIT QUICKLY INTO PLACE ON BOARD.

♪♪

SO, HERE WE GO, THIS IS WHERE WE'RE GOING TO CONNECT

THE CABINS TO THE SHIP WITH THAT PLUG.

THIS IS PLUG-N-PLAY.

THE CABIN IS JUST FINISHED,

WE JUST NEED TO CONNECT THE CABINS TO THE SHIP.

AND IT WILL WORK AS SIMPLE AS THAT NOW.

IT WOULD BE IMPOSSIBLE TO PRODUCE MERAVIGLIA ON TIME

IF WE WOULD MOVE 100% OF THE CABIN ON BOARD --

WITHOUT ANY DOUBT.

Narrator: AFTER A MERE 25 MINUTES,

THE ASSEMBLY OF THIS MODULAR CABIN IS COMPLETE.

ITS NEXT STOP IS THE SHIPYARD.

♪♪

BUT THE TEAM MUST FIRST GEAR UP

TO FLOAT THE SHIP TO A DIFFERENT HARBOR

BEFORE WORKERS CAN INSTALL THE VESSEL'S CABINS,

RESTAURANTS, AND ENTERTAINMENT ZONES.

♪♪

AND BEFORE THEY MOVE THE SHIP, THEY MUST FIRST FIT

ITS TWO MASSIVE PROPELLERS ONTO THE STERN.

LUIC MARON FACES THE DAUNTING TASK

OF DESIGNING THE COMPLEX PROPULSION UNITS.

THEY MUST BE CAPABLE OF PROPELLING THIS ENORMOUS SHIP

WITHOUT COMPROMISING THE COMFORT OF THE JOURNEY.

THIS IS THE PROBLEM -- WHEN A SHIP'S PROPELLER ROTATES,

IT CREATES A VORTEX OF LOW PRESSURE BEHIND THE BLADES

MADE FROM MILLIONS OF TINY AIR BUBBLES.

THIS PROCESS IS CALLED CAVITATION.

WHEN THESE BUBBLES IMPLODE,

THEY SEND OUT SHOCK WAVES THROUGH THE WATER,

WHICH HIT THE PROPELLER AND THE SHIP'S HULL.

IF ENOUGH BUBBLES IMPLODE AT ONCE,

THIS CAN CAUSE VIBRATIONS THAT RUN THROUGH THE SHIP.

THESE CAN CREATE AN UNCOMFORTABLE RIDE

FOR THE PASSENGERS AND CREW.

WITH THE STAKES HIGH FOR THIS GIGANTIC BILLION-DOLLAR VESSEL,

NO OFF-THE-SHELF PROPELLER DESIGN WILL WORK.

SO LUIC MUST DEVELOP A ONE-OF-A-KIND SOLUTION.

Narrator: ENGINEERS ARE CONSTRUCTING

ONE OF THE LARGEST CRUISE SHIPS EVER CONCEIVED,

BUT TO PREVENT THE VESSEL FROM VIBRATING WHILE AT SEA,

ENGINEER LUIC MARON

HAD TO DEVELOP ONE-OF-A-KIND PROPELLERS.

TO TRY AND MINIMIZE VIBRATION,

HE'S DESIGNED A PROPELLER WITH FIVE BLADES,

PERFECTED THEIR SHAPE, ANGLE,

AND DISTANCE FROM THE HULL,

AND THE SPEED AT WHICH THEY WILL ROTATE

TO MAKE SURE THAT THE SHIP

GLIDES SMOOTHLY THROUGH THE WATER.

♪♪

BUT ACTUALLY BUILDING SUCH INTRICATE PROPELLERS

IS NO SIMPLE TASK.

♪♪

I LOVE MY JOB FOR SURE.

I LOVE TO MAKE THE BEST PROPELLERS IN THE WORLD.

Narrator: WORKERS CAST THE PROPELLERS

FROM A SPECIAL MOLTEN BRONZE ALLOY --

A MIXTURE OF COPPER, ALUMINUM, IRON, AND NICKEL.

THE CRUISE PROPELLER BLADES ARE VERY BIG BLADES.

Narrator: THEY CAST THE 28-TON PROPELLER IN SEPARATE PARTS --

THE BLADES AND THE CENTRAL HUB.

WORKERS FILL A SERIES OF BOXES WITH RESIN-BONDED SAND

TO CREATE THE MOLDS FOR THE BLADES.

Traba: WHAT WE DO HERE IS TO PUT SANDBOX IN FRONT OF THE ROBOT,

AND THEN THE ROBOT WILL BE ABLE TO REMOVE THE SAND

AND CREATE THE FINAL SHAPE OF THE MOLD.

Narrator: THEY MUST POUR THE MOLTEN ALLOY INTO THE MOLD

WITHOUT STOPPING TO AVOID ANY IMPERFECTIONS

THAT COULD COMPROMISE ITS STRENGTH.

WHEN WE ARE POURING, IT'S VERY IMPORTANT

THAT THE MATERIAL IS GOING INSIDE THE PART

WITH THE RIGHT VELOCITY.

OTHERWISE, WE CAN HAVE OXIDES

OR OTHER KIND OF DEFECTS THAT WILL APPEAR.

♪♪

Narrator: IT TAKES JUST MINUTES TO FILL THE MOLD,

BUT TWO DAYS FOR THE BLADE TO COOL

AND HARDEN FROM AROUND 2,200 DEGREES FAHRENHEIT.

THEN THEY REMOVE THE BLADE FROM ITS MOLD

AND GRIND ITS SURFACE SMOOTH

TO MAKE SURE IT GLIDES THROUGH THE WATER.

A COMPUTER-GUIDED ROTATING CUTTING HEAD

REMOVES LAYER AFTER LAYER OF UNWANTED MATERIAL.

IT'S VERY IMPORTANT THAT WE BUILD THESE PROPELLERS PRECISELY,

OTHERWISE, WE CAN HAVE BIG IMPERFECTIONS ON THE SURFACE.

AND THIS WILL AFFECT TO THE PERFORMANCE OF THE PROPELLER,

AND THE PASSENGER WILL BE AFFECTED BY THAT.

Narrator: FOR 25 HOURS, THIS CUTTING-EDGE ROBOT

SMOOTHS OVER THE BLADE THOUSANDS OF TIMES,

POLISHING AWAY EVERY LAST DEFECT TO AVOID A BUMPY RIDE.

WHEN WE ACHIEVE THE DELIVERY,

WE FEEL VERY WELL ON THE TEAM.

Narrator: BUT USING PROPELLERS THIS LARGE CREATES ANOTHER BIG PROBLEM --

BECAUSE THEIR GARGANTUAN SIZE MAKES MANEUVERING DIFFICULT.

THE PROPELLERS ON MOST SHIPS ARE CONNECTED TO THE HULL

IN A FIXED POSITION.

TO STEER THE SHIP, THE CAPTAIN USES A RUDDER,

BUT THIS LIMITS THE VESSEL'S MANEUVERABILITY.

FOR A CRUISE SHIP AS LARGE AS MERAVIGLIA,

NAVIGATING THROUGH THE TIGHT PORTS

AT POPULAR DESTINATIONS

WOULD BE NEARLY IMPOSSIBLE.

TO SOLVE THIS PROBLEM, THE ENGINEERS PLAN TO ATTACH

THESE MASSIVE PROPELLERS

TO TWO GIANT ROTATING THRUSTERS CALLED AZIPODS.

THESE HUGE PODS ARE DESIGNED TO SPIN A FULL 360 DEGREES.

THE ROTATING PODS TOGETHER WITH SMALL THRUSTERS IN THE BOW

SHOULD MAKE CONTROLLING THE SHIP MUCH EASIER

AND ALLOW THIS GIANT TO BREEZE INTO THE TIGHTEST OF PORTS.

TIPPING THE SCALES AT AROUND 190 TONS,

IT TAKES 10 WEEKS TO ASSEMBLE A SINGLE AZIPOD UNIT.

♪♪

THE COMBINED PROPELLER AND POD WEIGH ABOUT 220 TONS APIECE.

INSTALLING THEM ONTO THE VESSEL'S STERN

WILL BE A HUGE CHALLENGE.

THE SLIGHTEST DENT CAUSED DURING INSTALLATION

COULD DELAY THIS BILLION-DOLLAR SHIP BY MONTHS.

Narrator: TO PREVENT AN UNCOMFORTABLE JOURNEY,

WORKERS ARE ATTEMPTING TO INSTALL TWO 220-TON AZIPODS

ON THIS MEGA-CRUISE SHIP WITH NO HICCUPS.

THE HUGE CRANE LOWERS THE UNITS DOWN INTO THE DOCK.

♪♪

WORKERS THEN CAREFULLY SLIDE THEM UNDERNEATH THE SHIP

BEFORE LOCKING THEM INTO POSITION.

Rolando: SO AFTER NOW, THE PROGRESS IS GOOD ENOUGH,

EVERYTHING IS ACCORDING TO THE SCHEDULE.

Narrator: AND WITH THE PODS ATTACHED,

THE HULL OF MERAVIGLIA IS FINALLY COMPLETE.

♪♪

INSIDE, THE VAST 315-FOOT LONG, 2-STORY HIGH PROMENADE

THAT RUNS DOWN THE CENTER OF THE SHIP IS TAKING SHAPE.

♪♪

BUT BEFORE THE TEAM CAN INSTALL THE VESSEL'S INTERIOR,

WORKERS MUST MOVE THE SHIP TO THE HARBOR WHERE THE CABINS ARE.

♪♪

TO DO THIS, THEY MUST FLOAT THE PROTOTYPE VESSEL

FOR THE FIRST TIME.

THIS IS A MAJOR MILESTONE FOR THE COMPANY BOSSES

WHO'VE ARRIVED TO WITNESS THE EVENT.

♪♪

IT TAKES EIGHT HOURS TO FILL THE IMMENSE DRYDOCK.

♪♪

AND LATER THAT NIGHT, SHE'S FLOATING AND READY TO MOVE.

MERAVIGLIA IS SO BIG, IT TAKES FIVE TUGBOATS

TO CAREFULLY TOW HER TO HER NEW BERTH.

♪♪

GIUSEPPE'S TEAM NOW HAS THEIR WORK CUT OUT.

THEY HAVE TO START PUTTING IN THE 2,244 CABIN UNITS

CONSTANTLY DELIVERED TO THE HARBOR EACH DAY.

Maresca: IT'S A MASSIVE CHALLENGE

TO GET ALL THE CABINS INSTALLED IN TIME.

FROM 6:00 IN THE MORNING, WE WILL HAVE A TRUCK COMING HERE

AND CABINS LOADING AND LOADING AND LOADING.

Narrator: TO KEEP PACE WITH THE RELENTLESS SUPPLY OF CABINS,

GIUSEPPE AND THE TEAM PLAN TO USE AN INGENIOUS TECHNIQUE

TO INSTALL THEM.

♪♪

SPECIAL HOLES IN THE SIDE OF THE SHIP PROVIDE ACCESS

TO SLIDE THE CABINS ON BOARD QUICKLY.

♪♪

THE NEXT STEP IS TO SECURE A GIANT ELEVATOR

ONTO THE OUTSIDE OF THE SHIP TO REACH THEM,

WHICH WILL HELP LOAD AND LIFT EACH CABIN ONTO THE SHIP.

SPECIAL ROLLERS ALLOW THE TEAM TO PUSH THE CABINS ON BOARD,

SQUEEZING THEM THROUGH DIVIDING WALLS,

AND AROUND THE TIGHT CORNERS

SO THE WORKERS CAN ULTIMATELY SLIDE THEM

INTO THE CORRECT SPOT.

IT'S A BIT LIKE UNWRAPPING A NEW CHRISTMAS PRESENT EVERY DAY.

♪♪

♪♪

THIS IS WHERE WE GET OFF.

♪♪

STOP.

PUSH, PUSH.

Narrator: IT'S A TIGHT SQUEEZE TO GUIDE

EACH OF THE 1 1/2-TON CABINS THROUGH THE MAZE OF EQUIPMENT

AND WORKERS THAT CRAM THE INSIDE OF THE VESSEL.

ONE OF THE BIGGEST PROBLEMS IS THE SPACE

TO PUT THE CABIN IN POSITION.

AT SUMMERTIME LIKE THIS, IT'S A LOT OF HARD WORK.

♪♪

PULL!

Narrator: IF A SINGLE CABIN GETS DAMAGED,

IT COULD HOLD UP THE INSTALLATION

OF AN ENTIRE DECK OF ROOMS.

ALL THE WORK ONBOARD ARE CONNECTED

SO WE CANNOT HAVE DELAY.

THIS IS INSIDE OF THE CABIN.

HERE WE HAVE THE TOILET, THIS IS THE WARDROBE,

AND HERE WE HAVE THE BEDS.

THERE ARE NO VISIBLE DAMAGE FROM THE TRANSPORTATION.

YES, CABIN IS FINE.

ANOTHER ONE DOWN, AND WE HAVE

STILL MORE 1,000 TO PUT ON BOARD.

Narrator: WHILE GIUSEPPE'S TEAM MUST KICK IT UP A NOTCH...

...ON THE LOWER DECKS,

WORKERS ARE RACING TO BUILD THE SHIP'S CAVERNOUS PROMENADE.

THIS SPACE IS BEING DESIGNED

TO LOOK LIKE A MEDITERRANEAN-STYLE SEAFRONT.

THE 2-STORY HIGH PROMENADE WILL BE FILLED

WITH SHOPS, RESTAURANTS, AND CAFéS.

THERE'S A HUGE AMOUNT OF WORK FOR THE TEAM STILL TO DO.

THEIR BIGGEST JOB IS INSTALLING

THE SHIP'S GIANT, DISTINCTIVE L.E.D. CEILING.

Narrator: INSTEAD OF A STANDARD GLASS SKYLIGHT

TO COVER THE PROMENADE CEILING,

THE TEAM PLANS TO BREAK WITH TRADITION.

THEY'RE PREPARING TO INSTALL

A NEVER-BEFORE-ATTEMPTED CURVED L.E.D. SCREEN

DESIGNED AT 262 FEET LONG

AND RUNNING THE LENGTH OF THE PROMENADE.

INSTALLING IT WON'T BE EASY,

AND WORKERS MUST CAREFULLY PIECE TOGETHER

1,450 INDIVIDUAL L.E.D. PANELS

TO CREATE THE CURVED, DOMELIKE STRUCTURE.

ONCE COMPLETE, THIS L.E.D. SCREEN

SHOULD BE ABLE TO DISPLAY ANYTHING

THE SHIP'S CREW DESIRES --

CHANGING THE AMBIENCE OF THE ENTIRE PROMENADE

AT THE TOUCH OF A BUTTON.

♪♪

♪♪

BUT PUTTING IT TOGETHER IS NOT EASY.

IT TAKES THREE MONTHS TO INSTALL ALL 1,450 L.E.D. PANELS

ON THE GIANT, CURVED FRAME.

♪♪

THOUSANDS OF CABLES CONNECT THE PANELS TOGETHER.

♪♪

IF JUST A SINGLE CABLE IS INCORRECTLY CONNECTED,

THE SCREEN WON'T FUNCTION PROPERLY.

WITH ALL THE PANELS IN PLACE, IT'S TIME FOR THE BIG TEST --

WILL ALL THE SECTIONS OF THE 262-FOOT-LONG SCREEN LIGHT UP?

WHAT WE ARE LOOKING AT TODAY IS TO HAVE A COMPLETE

AND FULL IMAGE ON ALL THE VAULT WITHOUT ANY PROBLEM --

WITHOUT ANY PIXEL MISSING.

OF COURSE, THE EXPECTATION OF THE OWNER

IS TO HAVE A PERFECT PICTURE

FROM THE BEGINNING TO THE END OF THE VAULT.

SO, A VERY BEAUTIFUL CHALLENGE FOR US,

AND LET'S SEE NOW WHAT HAPPENS.

Narrator: BUT IT'S NOT LONG BEFORE THEY RUN INTO TROUBLE.

Baldin: WE HAVE ONE BIG BLACK HOLE.

Narrator: THE TEAM TRIES TO TRACK DOWN THE CAUSE OF THE PROBLEM.

YES. NOTHING CHANGED.

NO, NO, NO.

WITH THE MAIDEN VOYAGE JUST 15 WEEKS AWAY,

CAN THEY IDENTIFY THE PROBLEM WITHOUT DELAYS?

Narrator: WITH ONLY 15 WEEKS

UNTIL ONE OF THE PLANET'S LARGEST CRUISE SHIPS SETS SAIL,

THE ENGINEERS ARE WORKING TO FIX A MAJOR GLITCH

WITH ITS DISTINCTIVE L.E.D. CEILING.

WE ARE SOLVING PROBLEM AFTER PROBLEM.

WHEN YOU FIND THE PROBLEM, YOU HAVE TO SOLVE IT

AND THEN GO TO THE NEXT STEP.

Narrator: THEY SOON FIGURE OUT WHY THE PANEL ISN'T WORKING.

A REPLACEMENT CABLE FIXES THE GLITCHES

WITH THE SHIP'S UNIQUE L.E.D. CEILING.

AS YOU CAN SEE, THE VIDEO AND THE PICTURE ARE SENT CORRECTLY

TO ALL THESE L.E.D. PANELS.

SO, YES, IT'S VERY GOOD

AND WE ARE VERY HAPPY WITH THIS RESOLUTION.

Narrator: THERE ARE NOW JUST NINE WEEKS TO GO

UNTIL THE CRUISE SHIP MERAVIGLIA

SETS SAIL ON HER MAIDEN VOYAGE.

BUT BEFORE THEY COMPLETE THE INSTALLATION,

THE SHIP NEEDS TO LEAVE ITS BERTH

FOR A CRUCIAL SERIES OF TESTS.

VERY EXCITING, YES.

WE'LL BE THREE DAYS WITHOUT SLEEPING FOR SURE.

Narrator: 390 ENGINEERS, MECHANICS, AND CREW

ARE BOARDING THE SHIP TO TAKE IT OUT

ONTO THE OPEN OCEAN FOR THE VERY FIRST TIME.

LET'S GO, BOAT.

Narrator: OVER THE NEXT THREE DAYS AND NIGHTS,

THEY WILL PUT ALL ITS SYSTEMS THROUGH A SUCCESSION

OF GRUELING TESTS CALLED SEA TRIALS

TO PROVE THAT THE SHIP IS SAFE TO CARRY OVER 5,000 PASSENGERS.

[ INDISTINCT TALKING ]

[ RADIO CHATTER ]

THIS IS THE MOMENT

THAT EVERYBODY HAS BEEN WORKING TOWARDS.

IT'S MAKE OR BREAK FOR GAETANO'S TEAM.

♪♪

THE MAN MERAVIGLIA MUST IMPRESS

IS LEAD INSPECTOR JEAN-LUC KERNEUR.

♪♪

♪♪

THE TEAM PUSHES THE VESSEL TO ITS VERY LIMIT

OVER THE NEXT 72 HOURS.

THEY TEST ITS FIRE-SAFETY EQUIPMENT.

THEY ASSESS HOW EASILY EMERGENCY CREWS CAN REACH A HELICOPTER...

...AND HOW QUICKLY THE ANCHOR DEPLOYS.

ONE OF THE MOST CRITICAL TESTS INVOLVES THE SHIP'S PROPELLER.

IT MUST CREATE NO NOISE OR VIBRATION

THAT COULD RUIN THE PASSENGERS' CRUISE.

WHILE THE SHIP SAILS AT FULL SPEED,

THE TEAM WORKS THEIR WAY FROM DECK TO DECK

LISTENING FOR EXCESSIVE LEVELS.

FINALLY, THEY TEST THE GIANT AZIPODS

THAT BOTH PROPEL AND STEER THE VESSEL.

THE CREW WILL PUSH THE GIANT PODS BEYOND THEIR LIMITS

BEFORE UNDERTAKING A CRITICAL CRASH-STOP TEST.

GENTLEMEN, WE ARE GOING TO DO CRASH-STOP TEST.

Narrator: A CRASH STOP INVOLVES USING THE AZIPODS

TO BRING THE SHIP TO A COMPLETE HALT

FROM A SPEED OF 21 KNOTS AS QUICKLY AS POSSIBLE.

[ BEEPING ]

THIS MANEUVER COULD BE CRUCIAL IN AN EMERGENCY,

LIKE AVOIDING A COLLISION.

SHIP SPEED LESS THAN 19, 18, 17,

16, LESS THAN 15.

THEY SPIN THE AZIPODS INTO FULL REVERSE.

10 KNOTS.

THE MAMMOTH VESSEL GRINDS TO A HALT IN 4 MINUTES 49 SECONDS,

BUT IS THIS FAST ENOUGH?

Narrator: AFTER A TENSE FEW DAYS AND AROUND 60 TESTS,

THIS ADVANCE PROTOTYPE SHIP AND HER CREW RETURN TO THE SHIPYARD.

IT'S TIME FOR INSPECTOR JEAN-LUC TO DELIVER HIS VERDICT.

♪♪

THIS IS A HUGE RELIEF FOR GAETANO.

OVER THE NEXT NINE WEEKS, THERE'S A FRANTIC RACE

TO FINISH INSTALLING THE PROMENADE.

♪♪

ALONGSIDE WORKERS,

THE ENTERTAINERS PRACTICE THEIR ROUTINES.

AND CHEFS FIRE UP THE KITCHENS

AS THE CLOCK COUNTS DOWN TO THE MAIDEN VOYAGE.

♪♪

TWO YEARS AFTER WORK BEGAN ON ITS CONSTRUCTION,

MERAVIGLIA LEAVES THE SHIPYARD.

ITS DESTINATION IS THE PORT OF LE HAVRE IN NORTHERN FRANCE

WHERE THE VESSEL WILL BE CHRISTENED

AHEAD OF HER MAIDEN VOYAGE.

♪♪

♪♪

BUT WHILE AT SEA, CREWS WORK AROUND THE CLOCK.

IT'S TIME NOW TO BE SURE THAT THE SHIP WORKS AND WORKS WELL.

Narrator: IT'S A SCRAMBLE TO COMPLETE THE FINISHING TOUCHES

AS THE SHIP CLOSES IN ON LE HAVRE.

AT LE HAVRE PORT, AN EVENTS TEAM

PREPARES FOR THE VESSEL'S GRAND ARRIVAL.

♪♪

♪♪

TODAY'S THE DAY THE SHIP HAS REACHED LE HAVRE.

EVERYTHING IS FINALIZED.

ALL THE TOUCHUPS HAVE BEEN COMPLETED.

WE ARE VERY, VERY EXCITED FOR THIS EVENT,

BUT THE SHIP IS READY, WE ARE READY, AND LET'S GO.

AS THE SUN BEGINS TO SET, THE STARS COME OUT.

CELEBRITIES, V.I.P.s,

AND EXECUTIVE CHAIRMAN PIERFRANCESCO VAGO

GATHER TO WELCOME THE SHIP.

Vago: LADIES AND GENTLEMEN, I WOULD LIKE TO THANK THE YARDS.

THEY'VE DONE AN AMAZING JOB

CREATING THE MOST INNOVATIVE CRUISE SHIP TODAY.

PLEASE JOIN ME TO GIVING A BIG ROUND OF APPLAUSE

FOR ALL OF THE WORKERS AND ALL OF THEM.

THANK YOU.

[ APPLAUSE ]

Narrator: IN A TIME-HONORED TRADITION,

THE SHIP WILL BE CHRISTENED BY A GODMOTHER.

TONIGHT, ACTRESS SOPHIA LOREN WILL CUT THE RIBBON.

[ APPLAUSE ]

[ APPLAUSE ]

THANK YOU. MERCI.

Vago: ARE YOU READY?

5...4...3...

2...1.

GO!

[ CHEERS AND APPLAUSE ]

Narrator: IT'S TAKEN 3,000 PEOPLE

MORE THAN 9 MILLION HOURS OF HARD WORK

TO COMPLETE THE FIRST VESSEL

IN A BRAND-NEW CLASS OF GIANT CRUISE SHIPS.

♪♪

Maresca: FINALLY, THE SHIP IS READY, IT'S LOOKING GREAT,

AND I'M VERY HAPPY THAT OUR WORK PRODUCED THIS.

I'M VERY, VERY HAPPY.

ALL OUR TEAM ARE WORKING VERY, VERY HARD THESE TWO YEARS.

SO, WE ARE VERY PROUD AND THIS CRUISE SHIP

HAS BEEN A VERY BIG CHALLENGE,

BUT IT'S IMPORTANT THAT THE RESULT IS GOOD.

Narrator: THE FOLLOWING MORNING, THE FIRST PASSENGERS BOARD,

AND THE SHIP SETS SAIL ON HER MAIDEN VOYAGE

AROUND THE MEDITERRANEAN SEA.

♪♪

AND THE TEAM IS CERTAIN THE BILLION-DOLLAR INVESTMENT

TO BUILD THIS GIANT WILL PAY OFF.

AND THE TEAM IS CERTAIN THE BILLION-DOLLAR INVESTMENT