All language subtitles for Building Giants Series 1 Super Tunnel 720p

Narrator:
A PIONEERING TEAM OF ENGINEERS

IS DIGGING DEEP
ON SOMETHING MASSIVE.

NOW IT'S SHOWTIME.

WE CAN READ YOU
LOUD AND CLEAR.

THEY'RE ATTEMPTING
TO BUILD AN INNOVATIVE

$3.5 BILLION CIRCULAR RAILWAY

RIGHT UNDERNEATH THE HEART
OF AN HISTORIC CAPITAL CITY...

STARTING TO ROLL NOW.

WITH 17 BRAND-NEW STATIONS
AND 39 DRIVERLESS TRAINS.

TO BUILD THE BIGGEST
CONSTRUCTION PROJECT IN THE CITY

FOR 400 YEARS,

THE TEAM MUST BATTLE TOXIC SOIL

AND CATASTROPHIC FLOODS --

AND COLLAPSING EARTH.

Man: TIME-WISE, WE'RE RIGHT
ON THE LIMIT.

NO, FAILURE IS NOT AN OPTION.

Narrator: THIS UNIQUELY
CHALLENGING UNDERGROUND RAILWAY

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

♪♪

Narrator: THE HISTORIC CITY
OF COPENHAGEN

LIES ON THE EAST
COAST OF DENMARK.

ITS SPECTACULAR
ARCHITECTURE AND SIGHTS

ATTRACT MILLIONS
OF VISITORS EACH YEAR.

BUT THIS CREATES A PROBLEM
FOR THE CITY'S POPULATION --

THE CAPITAL'S ROADS
ARE CONGESTED.

COPENHAGEN'S
1.2 MILLION RESIDENTS

HAVE TO BATTLE CONSTANT GRIDLOCK

THAT BLOCKS MAJOR ROADWAYS.

THE CITY DOES HAVE A METRO,
BUT, BUILT IN 2002,

IT WAS NOT DESIGNED TO COPE
WITH TODAY'S PEAK DEMAND.

SO THAT'S WHY, IN 2011,

BENEATH THE CENTER
OF THIS HISTORIC CITY,

THIS TEAM OF ENGINEERS
BEGINS BUILDING

A TRAILBLAZING NEW
UNDERGROUND RAILWAY.

Man: IT'S PRETTY CHALLENGING
AND AN IMPORTANT PROJECT

BECAUSE IT IS SUPPOSED
TO GET 90 PERCENT

OF THE POPULATION
OF COPENHAGEN.

Narrator: CONSTRUCTED IN
A CIRCLE UNDERNEATH THE CITY,

THE NEW RAILWAY,
CALLED CITYRINGEN,

WILL BRING THE MAJORITY
OF THE POPULATION

WITHIN A 10-MINUTE
WALK TO A STATION,

DOUBLING THE METRO'S CAPACITY.

THE MAN TASKED WITH CONSTRUCTING

THE RAILWAY'S
CONGESTION-BUSTING TUNNELS

IS VALERIO VIOLO.

Violo: THE CITY OF COPENHAGEN
IS LOOKING AT US.

IT IS FOLLOWING THE PROGRESS
OF THE CONSTRUCTION

NOW ON A DAILY BASIS.

THEY REALLY WANT US TO FINISH

AND TO GET THE METRO
UP AND GOING,

SO THAT'S KIND OF A STRONG
PRESSURE ON OUR SHOULDERS.

Narrator: BUILDING A PROJECT
OF THIS MAGNITUDE

DIRECTLY BENEATH THE HEART
OF THIS HISTORIC CAPITAL

IS NO SIMPLE TASK.

Man: THERE ARE A LOT OF SAFETY
CHALLENGES FROM UNDERGROUND

WORKS THAT COME TOGETHER,
PROVIDES US WITH A LOT OF RISK

AND HAZARD THAT YOU DON'T
NORMALLY GET

IN THE NORMAL CONSTRUCTION
OF A BUILDING, FOR EXAMPLE.

Narrator: IN JUST EIGHT YEARS,
THIS IS THE MASSIVE RAILWAY

VALERIO AND THE COPENHAGEN
METRO TEAM MUST SOMEHOW BUILD.

THE PLAN IS TO CONSTRUCT 17
BRAND-NEW SUBTERRANEAN STATIONS

THAT WILL CIRCLE
THE CITY IN A RING.

EACH STATION WILL BE UNIQUE,

BUILT TO REFLECT
ITS SURROUNDING AREA.

UNDERGROUND, AT TRACK LEVEL,

PLATFORM EDGE DOORS
WILL SEPARATE COMMUTERS

FROM THE 19 MILES
OF FRESHLY DUG TUNNELS

THAT WILL TRANSPORT COMMUTERS
AROUND THE CITY IN MINUTES.

39 INNOVATIVE
DRIVERLESS TRAINS

WILL RUN THROUGH THE TUNNELS.

♪♪

EACH TRAIN WILL HAVE
THE CAPACITY

TO SHUTTLE 280 PASSENGERS

BETWEEN STATIONS
EVERY 90 SECONDS.

THE NEW METRO WILL BE ABLE
TO TRANSPORT

AROUND 70 MILLION PASSENGERS
A YEAR WHEN IT'S COMPLETE.

♪♪

Man:
IT'S GOING TO BE A BIG CHALLENGE

BECAUSE THE CITY ITSELF IS
RELATIVELY SMALL AND CONGESTED,

SO THERE ARE CHALLENGES
AHEAD, CHALLENGES

THAT EVERYBODY IS WILLING
TO TAKE ON ONBOARD AND FACE.

Narrator: BUILDING THE VAST
UNDERGROUND METRO

IN THIS JAM-PACKED CAPITAL CITY

INVOLVES A SERIES
OF KEY CHALLENGES.

THE TEAM NEEDS TO EXCAVATE
17 MASSIVE HOLES

RIGHT IN THE HEART
OF THE CITY.

INSIDE THEM, THEY WILL
BUILD THE SUNKEN STATIONS.

TO CONNECT UP EACH STATION,
VALERIO AND HIS TEAM

MUST EXCAVATE
THREE MILLION TONS OF EARTH

TO CREATE THE TWO CIRCULAR
TUNNELS FOR THE TRAINS.

HOT ON THE HEELS
OF THE TUNNELERS,

A TEAM OF TRACK LAYERS
MUST POSITION,

CONCRETE AND WELD TOGETHER
OVER 19 MILES OF RAIL TRACK.

ENGINEERS MUST ALSO CONSTRUCT
AND TEST

THE FLEET OF
39 NEW DRIVERLESS TRAINS.

ONE OF THE TEAM'S
GREATEST CHALLENGES

WILL BE TO CONSTRUCT
A STRETCH OF TUNNELS

THAT MUST PASS DIRECTLY
UNDERNEATH COPENHAGEN'S

HISTORIC CENTRAL TRAIN STATION

WHILE IT REMAINS OPEN.

♪♪

THE FIRST TASK IS
TO CONSTRUCT THE TUNNELS.

THESE MUST BE BUILT BEFORE WORK

INSIDE THE STATIONS
CAN CONTINUE.

WE HAVE 36 MONTHS
TO COMPLETE THE TUNNELING.

THERE IS ALWAYS THE POSSIBILITY
TO MAKE A MISTAKE IN TUNNELING,

AND WE NEED TO BE FOCUSED AND TO
MAINTAIN OUR CONCENTRATION.

Narrator:
AS THE SON OF A GEOLOGIST,

VALERIO IS NO STRANGER
TO THE UNDERGROUND.

HE HAS OVER 21 YEARS' EXPERIENCE
ON MINING PROJECTS

AROUND THE WORLD,

BUT THE CITYRINGEN TUNNELS POSE
HIS BIGGEST CHALLENGE TO DATE.

Violo: I NEVER HAD SUCH A BIG
PROJECT TO MANAGE

AND SUCH A BIG COMPANY
TO MANAGE ALL BY MYSELF.

THIS ONE WAS
A PRETTY CHALLENGING TASK.

[ FOREIGN ]

Narrator: TO EXCAVATE
THE 19 MILES OF TUNNELS ON TIME,

THE TEAM IS USING
A FLEET OF INNOVATIVE

DIGGING VEHICLES CALLED
TUNNEL BORING MACHINES,

OR TBMs FOR SHORT.

Violo: WE HAD FOUR MACHINES
WORKING AT THE SAME TIME

THIS MONTH UNDER COPENHAGEN.

Narrator:
EACH TBM IS 344 FEET LONG

AND IS A MOBILE
TUNNEL-BUILDING FACTORY.

AT THE FRONT, A GIANT 19-FOOT
ROTATING CUTTER HEAD

CLAWS AWAY AT THE EARTH.

THE EXCAVATED MATERIAL MOVES
AWAY FROM THE CUTTER HEAD

ON A CONVEYOR.

IT IS LOADED INTO CARTS
FOR A SMALL TRAIN TO TOW AWAY.

A ROBOT ARM INSTALLS PRECAST
CONCRETE SEGMENTS

TO LINE THE FRESHLY
DUG TUNNEL TUBES.

IT TAKES SIX SEGMENTS TO MAKE UP
A COMPLETE TUNNEL RING

4.6 FEET WIDE.

HYDRAULIC PISTONS THEN
PUSH THE MACHINE FORWARD

SO THE EXCAVATION PROCESS
CAN BEGIN AGAIN.

ON AVERAGE,
EACH TUNNEL DIGGING MACHINE

CAN INSTALL 18 RINGS A DAY AS IT
SNAKES ITS WAY UNDER THE CITY.

TUNNELERS HAVE BEEN DIGGING

COPENHAGEN'S TRICKY
SEA-LEVEL GEOLOGY

NONSTOP SINCE 2013.

THE MACHINES CLAW AWAY UP
TO 3,000 TONS

OF EARTH, SAND AND SUPER-HARD
ROCK EVERY DAY.

THEY DIG OUT AND LINE AN AVERAGE
OF 3.7 MILES OF TUNNEL PER YEAR,

BUT THIS IS A CRUCIAL DAY
FOR THE TUNNELING TEAM.

ONE OF THE FOUR MACHINES
IS BURROWING ITS WAY NORTH

TO WHAT WILL EVENTUALLY
BECOME TRIANGLEN STATION.

NOW IT MUST BREAK THROUGH

INTO THE HALF-BUILT
STATION STRUCTURE ITSELF

SO THAT THE TUNNELS
AND STATIONS CONNECT.

CLAUDIO RAMAZZINI IS IN CHARGE

OF THIS CRITICAL PART
OF THE OPERATION.

Man: THIS IS THE BREAKING SIDE
OF THE STATION.

BASICALLY,
AS YOU CAN SEE HERE,

HERE WE HAVE
THE CONCRETE BLOCK,

AND INSIDE OF THIS
CONCRETE BLOCK,

WE HAVE ONE OF OUR BIG
TUNNEL-BORING MACHINE,

AND IT'S ABOUT TO GET
IN THE STATION.

♪♪

Narrator: BUT THAT'S EASIER
SAID THAN DONE.

TO PREPARE FOR THE MACHINE'S
BREAKTHROUGH,

ENGINEERS HAVE BUILT
A GIANT CONCRETE BLOCK

AT THE PRECISE POINT
WHERE IT WILL ENTER.

THE BLOCK ACTS AS A PLUG
TO STOP EARTH AND GROUNDWATER

FLOWING INTO THE STATION
AS THE MACHINE EASES THROUGH.

WITHOUT THIS BLOCK,

THE PRESSURE FROM THE
SURROUNDING WATER IN THE GROUND

COULD CAUSE THE WALL
AROUND THE MACHINE TO COLLAPSE,

CREATING CATASTROPHIC DAMAGE,

BUT ALREADY THIS WORST-CASE
SCENARIO IS BECOMING A REALITY.

Narrator: IN COPENHAGEN,
ENGINEERS ARE BUSY BUILDING

THE CITY'S BIGGEST CONSTRUCTION
PROJECT IN 400 YEARS,

THE $3.5 BILLION
CITYRINGEN METRO.

AT THE MOMENT,
THE TUNNEL-BORING MACHINE

IS ABOUT 35 FEET
BEHIND THE BLOCK.

IF YOU GET CLOSER TO THE WALL,
YOU CAN HEAR THE NOISE

OF THE CUTTER HEAD
CUTTING THE CONCRETE.

Narrator:
FOR CLAUDIO AND THE TEAM,

THE STAKES ARE HIGH.

WE HAVE TO DO THE BREAKING
ON TIME TO STAY ON SCHEDULE,

SO THE TEAMS HERE
IN TRIANGLEN STATION

CAN FINISH BUILDING THE STATION.

Narrator: PAUL EVANS HEADS DOWN
TO MAKE THE FINAL CHECKS.

Man: SOME OF THE CONCERNS WE
HAVE WHEN THE ACTUAL TBM

LITERALLY BREAKS
THROUGH THAT CONCRETE

IS THE POSSIBILITY OF DEBRIS

FLYING QUITE A DISTANCE
AND INJURING PEOPLE.

Narrator: BUT, WITH THE
TUNNELING MACHINE

NOW JUST 16 FEET AWAY
FROM BREAKING THROUGH,

THE TEAM HITS A PROBLEM.

[ FOREIGN ]

GROUNDWATER STARTS FLOODING
INTO THE STATION

THROUGH A GAP IN THE TOP
OF THE CONCRETE BLOCK,

THREATENING THE ENTIRE PROJECT.

WE HAVE A PROBLEM HERE
OF WATER INFLOW,

SO WE HAD TO STOP
THE EXCAVATION.

WE NEED TO GET THIS
FIXED QUICKLY

SO THAT WE CAN PROCEED WITH
THE BREAKTHROUGH OPERATIONS.

WE DON'T WANT DELAY.

Narrator: GROUNDWATER IS FLOWING
THROUGH A GAP

BETWEEN THE OUTER EDGE
OF THE TUNNEL

AND THE PLATFORM CEILING.

UNSTOPPED, IT COULD
CATASTROPHICALLY FLOOD

THE TUNNELS.

TO STEM THE FLOW, VALERIO'S TEAM
MUST DRILL A RING OF HOLES

THROUGH THE TUNNEL SEGMENTS.

THE HOLES NEED TO BE
AT THE PRECISE POINTS

WHERE THE TUNNEL MEETS
THE STATIONS EXTERIOR WALL.

THEN THEY'LL INJECT
A SPECIAL TYPE OF RESIN

THROUGH THESE HOLES.

THE RESIN SOLIDIFIES
ON CONTACT WITH WATER

AND SHOULD FORM A WATERTIGHT
SEAL AROUND THE TUNNEL

TO PLUG THE LEAK.

♪♪

INSIDE, THE STATION ENGINEERS
BEGIN BATTLING THE FLOODWATER.

♪♪

Narrator:
IT TAKES A FRANTIC FEW DAYS

WORKING AROUND THE CLOCK

TO INJECT THE RESIN

AND MAKE
THE STATION WATERTIGHT.

WITH THE LEAK FIXED, AND WITH
JUST OVER TWO FEET TO GO,

THE TEAM PREPARES
TO BREAK THROUGH,

HOPING THE RESIN PLUG HOLDS.

Narrator:
THE STATION TEAM GATHERS

TO WITNESS THE MILESTONE.

IT'S AN ANXIOUS TIME
FOR WORKERS.

I'VE BEEN WAITING FOR 4 YEARS
FOR THIS MACHINE

TO ARRIVE ON THIS SIDE.

♪♪

OKAY. NOW I'M GOING TO CALL
THE PILOT AND SAY TO HIM,

"RESTART AND BREAK IN."

FINISH.
NO MORE DELAYS.

♪♪

THIS IS THE MOMENT OF THE TRUTH.

♪♪

♪♪

I'M VERY HAPPY NOW
BECAUSE WE ARE

WITH THE TUNNEL BORING MACHINE.

WE HAVE DONE THE BREAK-IN, SO...

GREAT MOMENT.

YEAH!

Narrator: SUCCESS --

THE TUNNELING TEAM
BREAKS THROUGH

AND JOINS UP WITH THE STATION
CREW FOR THE FIRST TIME.

[ CHEERING ]

BUT FOR CLAUDIO, THE HARD WORK
DOESN'T STOP HERE.

Ramazzini:
ALL OF THE PRESSURE GONE NOW,

JUST FOR A FEW HOURS,

AND THEN, AGAIN, PRESSURE

BECAUSE WE HAVE TO PUSH
THE TUNNEL BORING MACHINE

ON THE OTHER SIDE
OF THE STATION.

♪♪

Narrator: WITH THE TRICKY
BREAKTHROUGH BEHIND THEM,

THE FOUR TBMs PICK UP THE PACE.

I CAN SET THIS TO...
FIFTY PERCENT.

YES.

Narrator:
THE MACHINES CHEW THROUGH

NEARLY 3,000 TONS
OF DIRT AND STONE

EVERY DAY AS THEY BURROW
UNDERNEATH THE CITY.

BUT GETTING RID OF ALL
THIS EXCAVATED EARTH

IS ANOTHER HUGE CHALLENGE
FOR VALERIO'S TEAM.

Violo: THE TBM CAN BUILD
A LOT OF RINGS PER DAY.

NOW CONSIDERING THE DISTANCE,

WE ARE DOING 18 RINGS
PER DAY ON AVERAGE.

Narrator: AFTER THE MACHINE
BUILDS EACH RING,

THE EXCAVATED EARTH IS CARRIED
AWAY FROM THE CUTTER HEAD

AND DUMPED INTO
A SERIES OF CARTS.

ONCE FULL, A SMALL TRAIN
PULLS THEM OUT TO BE EMPTIED.

♪♪

ANY DELAY OF GETTING RID
OF THE WASTE

COULD HOLD UP
THE ENTIRE PROJECT.

Narrator: BUT COPENHAGEN'S
UNIQUE GEOLOGY

CREATES A PROBLEM.

Narrator: AN OLD INDUSTRIAL PART
OF THE CITY

HAS LEFT BEHIND A TOXIC LEGACY.

THIS MAKES THE TASK OF MANAGING
THE EXCAVATED EARTH

EVEN TOUGHER.

I'M TAKING SOME SAMPLES TO BE
SENT OFF FOR LAB TESTING.

Narrator: EVERY DAY,
CHRISTIAN'S TEAM MUST SAMPLE

A TRAINLOAD OF MUCK
FOR TRACES OF CONTAMINANTS,

BUT HE CAN'T AFFORD
TO HOLD UP TUNNELING.

THESE SAMPLES,
TOGETHER WITH THE MUCK,

SENT FOR ANALYSIS EVERY DAY
WHILE THE TBM IS MINING.

Narrator: WORKERS EMPTY THE DIRT
AND RUBBLE

FROM THESE CARTS
INTO TEMPORARY PITS

WHILE THEY WAIT
FOR THE TEST RESULTS.

♪♪

Tjustrup: EVERY DAY, WE GET THE
DECISIONS FROM THE AUTHORITIES,

AND THEN WE INSTRUCT
THE WORK SITE MANAGER

HOW THEY SHOULD
ORGANIZE THE DEPOSIT

AND WHICH MUCK PIT IS CLEAN

AND WHICH MUCK PIT
IS CONTAMINATED.

Narrator: IT TAKES 24 HOURS

FOR THE RESULT
OF EACH TEST TO COME THROUGH.

THE TEAM ANXIOUSLY
AWAITS THE RESULTS.

Narrator:
ENGINEERS ARE BUSY TUNNELING

UNDERNEATH THE CITY
OF COPENHAGEN

TO CREATE A MASSIVE NEW SUBWAY,

BUT THEY MUST FIND OUT
IF THE SOIL IS TOXIC.

-HI, KLAUS.
-HI.

WHERE IS THE MUCK GOING TODAY?

IS IT CLEAN?
IT'S CLEAN MUCK.

OKAY.
THANK YOU VERY MUCH.

ALL THE MUCK TODAY IS CLEAN,

AND IT'S GOING TO BE DISPOSED OF
TO THE CLEAN SOIL FACILITY.

♪♪

MAYBE THE SITUATION
IS DIFFERENT TOMORROW.

WE'LL HAVE TO WAIT AND SEE.

Narrator: EACH TRUCKLOAD OF MUCK

TRAVELS FIVE MILES
NORTH OF THE CITY

TO THIS UNIQUE FACILITY.

♪♪

THIS IS NO ORDINARY WASTE DUMP.

WORKERS HERE ARE USING
THE CLEAN COIL

TO EXTEND THE CITY
OUT INTO THE SEA.

THEY'RE FILLING IN AN AREA
OF THE WATERFRONT

OVER A HALF SQUARE MILE
TO CREATE SPACE

FOR A NEW PORT
AND PARK LAND.

Tjustrup: THE AREA IS GOING TO
INCREASE THE AREA OF COPENHAGEN

BY ONE PERCENT.

THE TOTAL AREA
WHERE WE ARE RIGHT NOW

IS GOING TO BE USED FOR
THE PUBLIC IN COPENHAGEN,

FOR FISHING, FOR HAVING PICNICS

AND FOR DOING
SOME KIND OF PLAYING

AND WHATEVER PEOPLE LIKE TO DO.

TODAY IT'S A BIT COLD.

I'M FREEZING, BUT WHEN
THE SUMMER IS COMING,

MAYBE WE CAN TAKE
A SWIM IN THE SEA

AND DO SOME SUNBATHING.

♪♪

Narrator: UNDERGROUND,
THE TUNNELING TEAM

IS STILL WORKING
AS FAST AS THEY CAN.

[ FOREIGN ]

EACH TIME THE TEAM BREAKS
THROUGH INTO A STATION

THEY FACE THE SAME BATTLE,

TO DRAG THIS 700-TON TUNNELING
MACHINE THROUGH THE PLATFORM

SO THEY CAN CONTINUE DIGGING.

Man: EVERYBODY WANTS TO SEE
THE MACHINE COME IN,

BUT THEN A LOT OF PEOPLE
WANT TO SEE IT LEAVE AGAIN

BECAUSE THERE'S A LOT OF WORK
THAT HAS TO CONTINUE FROM THERE.

THERE ARE DEADLINES TO MEET.

Narrator: THE HIGHLY SPECIALIZED
TRACKLAYERS

ARE HOT ON THEIR HEELS.

VALERIO AND HIS TEAM
WITH THE TUNNEL BORING MACHINE

ARE FURIOUSLY CHOMPING
THROUGH VIRGIN DIRT.

OUR GOAL IS TO BE AS CLOSE
AS POSSIBLE BEHIND HIS TEAM

SO THAT WE CAN ALL FINISH
THIS PROJECT ON TIME.

WE HAVE TWO TUNNELS,
17 STATIONS.

WE'VE GOT A DEADLINE.

WE NEED TO ACHIEVE THIS FAST.

Narrator: PAUL AND HIS TEAM NEED
TO POSITION THE TRACK,

SECURE IT WITH CONCRETE,
AND JOIN EACH SECTION TOGETHER

WITH ABSOLUTE PRECISION.

IT'S NO SMALL FEAT.

TO HELP THEM INSTALL EACH PIECE
IN THE RIGHT SPOT,

THEY ARE USING
AN INNOVATIVE MACHINE.

THIS RAIL-LAYING GANTRY CRANE

IS FITTED WITH
PRECISION-GRABBING ARMS

TO PICK UP AND POSITION
THE FLEXIBLE PIECES OF RAIL.

Man: THERE'S A LOT OF SKILL
INVOLVED IN PICKING THEM UP

IN THE RIGHT POSITION
TO MINIMIZE DEFLECTION.

THEY DO MOVE AROUND
QUITE EASILY.

THEY HAVE TO BECAUSE THE TUNNEL
HAS SO MANY TWISTS AND TURNS,

IT NEEDS THAT FLEXIBILITY.

Narrator: THE FLEXIBLE RAIL
HELPS THE TRACK LAYERS

SNAKE A PATH THROUGH
THE CURVED TUNNELS.

Burley: WITH CURVATURE
IN ONE DIRECTION,

WE ALSO COME ACROSS
THE PROBLEM OF ONE ROW

GETTING LONGER OR CREEPING
AHEAD OF THE OTHER.

SO EVERY SO OFTEN WE NEED TO
PERFORM A CUT

WITH A QUICK-CUT SAW TO MAKE
SURE THAT WE'RE BACK ON

A LEVEL PEG, AND...

Narrator: THEY MUST LEVEL UP
THE ENDS OF THE RAIL

SO THAT THE NEXT SET
OF TRACKS JOINS UP SMOOTHLY.

ANY BUMPS OR MISALIGNMENTS
COULD DERAIL A TRAIN.

THIS IS DEFINITELY, BY FAR,
THE MOST IMPORTANT STAGE

OF THE TRACK-LAYING PROCESS.

Narrator: PAUL'S TEAM
USES A PLUMB LINE

TO HELP THEM PUSH OR PULL
THE RAILS INTO POSITION

WITH PINPOINT ACCURACY.

Burley: WITHOUT THESE SORT
OF ACCURACIES,

THERE'S A CHANCE THAT
THE TRAIN COULD DERAIL,

AND I'M MY HEAD'S SORT
OF MOVING AROUND LIKE THIS,

I MAY AS WELL CATCH A BUS.

IT NEEDS TO BE SMOOTH.

PERFECT.

Narrator: WITH THE TRACKS
PERFECTLY IN PLACE,

THE TEAM MUST NOW LOCK THEM
INTO POSITION WITH CONCRETE.

THAT'S EASIER SAID THAN DONE.

TO SECURE THE NEXT
50 FEET OF TRACK,

THEY NEED TO PUMP AROUND
20 TONS OF WET CONCRETE

6 STORIES DOWN TO A MIXER
IN THE TUNNELS

AND FEED IT TO THE RAIL
CREW BEFORE IT SETS.

IT'S A LONG DISTANCE
IN A SHORT AMOUNT OF TIME.

Burley: 90 MINUTES IS THE TIME
THAT WE HAVE TO ENSURE

THAT THE CONCRETE
IS STILL IN A CONDITION

THAT WE CAN USE
TO LOCK THE SLEEPERS

INTO THEIR FINAL POSITION.

Narrator: IT TAKES OVER
40 MINUTES

JUST TO FILL EACH MIXER.

Burley: THERE'S AN ENORMOUS
AMOUNT OF PRESSURE

ON THESE GUYS -- 90 MINUTES
IS NOT A LONG TIME.

Narrator: THE LOAD REACHES
THE CONCRETING CREW

WITH JUST MINUTES TO SPARE.

♪♪

Burley: TIME-WISE, WE'RE RIGHT
ON THE LIMIT.

THESE GUYS HAVE TO WORK QUICK.

TIME IS CRITICAL.

THE MEN IN WHITE JUST PERFORMING
THE FINAL CONCRETE

FINISHING WORK BY HAND.

Narrator:
FOR THIS SECTION OF TUNNEL,

THEY FINISHED IN TIME.

Burley: TODAY, A GOOD DAY
IF WE GET 80 METERS DONE.

ONLY 31,500 METERS TO GO.

♪♪

♪♪

Narrator: WHILE WORK ON BOTH
THE TUNNELING

AND TRACK LAYING PICKS UP PACE,

1,200 MILES AWAY IN ITALY,

ENGINEERS ARE BUILDING
THE RAILWAY'S

39 NEW DRIVERLESS TRAINS.

HERE, THE TEAM ASSEMBLES
EACH OF THE TRAINS'

THREE INDIVIDUAL CARRIAGES,

INSTALLS THE DOORS AND WINDOWS

AND CONNECTS UP THE COMPLEX
ELECTRICAL SYSTEMS

THAT WILL PROVIDE
THE DRIVERLESS TRAIN CONTROLS.

ONCE BUILT, EACH TRAIN IS
SHIPPED TO THIS TEST FACILITY

WHERE DAVIDE MARANDOLA'S TEAM
ADDS THE FINISHING TOUCHES.

♪♪

Narrator: HIDDEN AT THE OTHER
END OF THE FACILITY

IS CITYRINGEN'S
HIGH SPEED TEST TRACK

WHERE EACH DRIVERLESS TRAIN MUST
PASS A SERIES OF CRITICAL TESTS.

TODAY, TECHNICIANS PLUG INTO
TRAIN 20'S COMPUTER CONTROLS

TO TRACK IT'S PERFORMANCE.

♪♪

Narrator: DAVIDE WILL PUSH THIS
TRAIN TO ITS LIMIT.

IT MUST ACCELERATE AND BREAK

WITHIN A SPECIFIED TIME
AND DISTANCE.

Marandola: IT'S CRUCIAL BECAUSE
WE NEED TO PROVIDE A TRAIN

THAT IS RELIABLE.

NOW WE ARE GOING
TO THE TEST TRACK.

Narrator:
IF THIS TRAIN FAILS,

IT COULD DELAY WORK
ON THE ENTIRE FLEET.

Narrator: AS PART OF
COPENHAGEN'S AMBITIOUS

$3.5 BILLION CITYRINGEN,

ENGINEERS ARE TESTING A NEW
FLEET OF DRIVERLESS TRAINS.

BUT FOR THIS CRUCIAL TEST,

A DRIVER MUST SIT IN
THE HOT SEAT.

Marandola: MICHAEL, CAN WE GET
THE FOUR-SIGNAL READY?

YEAH.

SO THE ACCELERATION
IS QUITE STRONG.

♪♪

OKAY.
NOW YOU CAN STOP.

♪♪

Narrator:
NOW FOR THE BRAKE TEST.

WE ARE STARTING.

THEN, WHEN WE REACH MAX SPEED,
WE MAKE MAX SERVICE BRAKE.

Narrator: EACH TRAIN MUST BE
ABLE TO STOP COMPLETELY

IN LESS THAN 180 FEET.

Marandola: OKAY.
NOW YOU CAN STOP.

LITTLE, YEAH.

OKAY.

YES.

OKAY.

Narrator:
AFTER A DAY ON THE TEST TRACKS,

IT'S THE MOMENT OF TRUTH.

HAS THIS TRAIN
PASSED BOTH TESTS?

Marandola: WE CAN EVALUATE
INCREASING OF THE SPEED,

SO THIS YELLOW LINE,
FROM ZERO TO 40.

THAT ACCELERATION WAS 1.25,

SO IT HAS BEEN GOOD --
REACHED IN GOOD WAY.

Narrator: THE BRAKING DATA SHOWS
THAT IT STOPPED AFTER

JUST 160 FEET,
UNDER THE TARGET.

♪♪

Narrator: THIS TRAIN HEADS
BACK TO THE BASE,

HAVING PASSED WITH
FLYING COLORS.

BUT WITH 19 MORE TRAINS
TO PUT THROUGH THIS TEST,

THERE'S STILL A LOT MORE WORK
FOR DAVIDE'S TEAM TO DO.

[ BEEPING ]

Narrator: AS TRAINS BEGIN TO
LINE UP READY TO ENTER SERVICE,

PAUL'S TRACK TEAM IS WORKING
24/7 TO INSTALL THE RAILS.

WITH A WELD EVERY 60 FEET
AND OVER 19 MILES OF TUNNEL,

IT'S A RELENTLESS BATTLE.

THOUSANDS
AND THOUSANDS OF WELDS.

Narrator: PAUL AND THE TEAM PLAN
TO USE AN INGENIOUS

AND SUPER FAST
WELDING TECHNIQUE

TO STOP THEM
FROM FALLING BEHIND.

THEY ARE PREPARING
A FIERY CHEMICAL REACTION

TO SUPER HEAT A MIXTURE
OF ALUMINUM AND IRON OXIDE

THAT CREATES A MIX
OF MOLTEN METAL.

THIS LIQUID METAL
SHOULD FILL THE GAP

BETWEEN THE RAILS
IN MERE MINUTES.

♪♪

THE ADVANTAGE IS THE ABILITY
TO JOIN TWO UNIQUE BITS OF RAIL,

CREATING ONE SEAMLESS
STRETCH OF RAILWAY LINE.

NOW IT'S SHOWTIME.

Narrator: THE CHEMICAL REACTION
IS INSTANTANEOUS.

♪♪

THE LIQUID METAL FLOWS FROM
THE BASE OF THE DRUM

INTO THE MOLD.

ANY EXCESS DRAINS INTO
THESE PANS ON EITHER SIDE.

Burley: IT'S CRITICAL THAT WE
WAIT THE RIGHT AMOUNT OF TIME

BEFORE REMOVING THE MOLDS.

IF WE REMOVE THE MOLDS
TOO EARLY,

THE METAL WILL RUN
AND FALL OUT OF THE JOINT.

IF WE REMOVE IT TOO LATE, WE RUN
THE RISK OF HAVING MOLTEN METAL

STUCK TO THE TRACK
WHICH IS VERY HARD TO REMOVE.

Narrator: ONCE READY,
THEY BREAK THE MOLD OFF

AND LEAVE THE WELD
TO COOL OVERNIGHT.

HERE WE CAN SEE
A THERMITE RAIL WELD

THAT WAS COMPLETED LAST NIGHT.

WE CAN SEE THAT THE RAIL GAP
THAT WE WITNESSED EARLIER

IS PERFECTLY FILLED WITH
THE MOLTEN METAL SOLUTION.

IT'S HAD AN INITIAL GRIND,

AND IT'S READY FOR THE FINAL
GRINDING LATER TOMORROW.

ONE RAIL WELD COMPLETED,
MANY THOUSANDS TO GO.

Narrator: THE SUPER FAST WELDING
HELPS PAUL'S TEAM

JOIN AROUND 590 FEET OF TRACK
EACH NIGHT.

♪♪

ACROSS TOWN, THE TEAM IS
GEARING UP TO TUNNEL UNDER

COPENHAGEN'S HISTORIC
CENTRAL STATION.

THIS ICONIC STATION
WAS BUILT IN 1911,

AND NOW 100,000 COMMUTERS USE
THIS CRUCIAL HUB EVERY DAY.

Man: IT'S REALLY IMPORTANT THAT
WE DON'T DO ANY DISRUPTION

TO THIS BECAUSE THIS IS
THE MAIN HUB

FOR CENTRAL COPENHAGEN,
AND ALL THE TRAINS HEADING OUT

TO OTHER PARTS OF DENMARK,

SO WE CANNOT AFFORD
TO CAUSE ANY DISRUPTION

TO THE STATION AT ALL.

Narrator: FOR THE RING OF
TUNNELS TO REACH

THEIR FINAL STATION,
ENGINEERS NEED TO TUNNEL

A MERE 49 FEET BELOW THIS
BUSY HUB.

NO TUNNELS HAVE COME THIS CLOSE

TO COPENHAGEN'S
OLDEST STATION BEFORE,

AND DIGGING SUCH HUGE HOLES

SO CLOSE TO THIS HISTORIC
BRICK-WALLED BUILDING,

IF NOT DONE RIGHT,
COULD CAUSE CATASTROPHIC DAMAGE

AND CLOSE THIS INTERNATIONAL
HUB FOR MONTHS.

PULLING THIS OFF WITHOUT A HITCH
WILL BE A HUGE CHALLENGE.

Narrator: IN COPENHAGEN,
ENGINEERS ARE CONSTRUCTING

THE CITYRINGEN METRO,

BUT THEY'RE TRYING TO FIGURE OUT

HOW TO TUNNEL UNDERNEATH THE
CITY'S ICONIC CENTRAL STATION

WITHOUT CAUSING IT TO COLLAPSE.

WELL, WHERE WE ARE AT THE MOMENT
IS RIGHT NEXT TO COPENHAGEN'S

MAIN CENTRAL STATION.

JUST BEYOND THAT FENCE LINE

IS WHERE THE TBMS WILL
COME THROUGH EVENTUALLY,

PASSING UNDER
THE EXISTING RAIL LINE.

Narrator: THE TEAM IS SO NERVOUS
ABOUT DIGGING THIS SECTION

OF TUNNEL THAT THEY HAVE
A SPECIAL CREW

THAT MONITORS
THE OPERATION 24/7.

IT RESTS ON THE SHOULDERS
OF SPYROS LATSENERE

TO MAKE SURE THE OLD STATION
DOESN'T START COLLAPSING.

Narrator: THE PLAN IS FOR
WORKERS TO EXCAVATE THE TUNNELS

UNDERNEATH THE HISTORIC STATION.

THERE'S A REAL RISK THAT THE
DIGGING COULD DISTURB THE EARTH

AROUND THE TUNNEL BORING MACHINE
CAUSING THE SOIL TO SHIFT

AND TRIGGERING THE BUILDINGS
ABOVE GROUND TO TILT.

TO MONITOR FOR THIS,
SPYROS AND HIS TEAM

HAVE INSTALLED AN INGENIOUS
NETWORK OF LASERS AND PRISMS

ALL OVER THE STATION TO CHECK
FOR ANY GROUND MOVEMENT.

THE LASER FIRES A BEAM
EVERY 30 MINUTES

TO RECORD THE POSITION
OF THE PRISMS.

IF THE SPOT THE LASER BEAM
HITS SUDDENLY CHANGES,

THIS MEANS THAT
THE PRISM HAS MOVED,

AND THE SYSTEM SENDS
AN ALERT BACK TO THE BASE.

Narrator: INCH BY INCH,
THE TUNNEL BORING MACHINE

SLOWLY SNAKES ITS WAY
UNDER THE MAIN STATION.

[ FOREIGN ]

Narrator: IT'S A TENSE TIME
FOR THE TUNNELING CREW,

AS THEY APPROACH THE POINT
WHERE THEY WILL MAKE THE FINAL

BREAKTHROUGH NEXT
TO THE MAIN STATION.

OKAY, GUYS.
WELCOME.

IT'S THE MOMENT THEY'VE
ALL BEEN WORKING TOWARDS.

Man:
THE MAIN FOCUS POINT TODAY

IS GOING TO BE
THE FINAL BREAKTHROUGH.

SO OF COURSE IT'S NOT JUST
A FINAL BREAKTHROUGH.

IT'S THE LAST BREAKTHROUGH
OF THE ENTIRE PROJECT.

WE'VE BEEN PART OF THIS PROJECT
NOW FOR THE LAST THREE YEARS,

AND IT ALL COMES TO THIS POINT
WHEN IT BREAKS THROUGH.

WE NEED TO KEEP OUR FOCUS
ON THE SAFE DISTANCE

FOR THE SPECTATORS,

AND ESPECIALLY
WITH THIS BREAKTHROUGH,

THERE'S GOING TO BE
A LOT OF PEOPLE

THAT WANT TO GET IN THERE.

THERE WILL BE A LOT
OF EYES ON US,

AND IN THAT RESPECT, WE WANT
TO MAKE SURE THAT WE DO THIS

AND IT'S A NICE
CLEAN BREAKTHROUGH

AND WITHOUT INCIDENT.
OKAY. THANK YOU.

OKAY.
THANK YOU, SIR.

Narrator: BUT JUST AS THE
TUNNELERS REACH

THE HALFWAY POINT
UNDER THE STATION,

SOME ALARMING READINGS ALERT
SPYROS' TEAM TO A PROBLEM.

Narrator: THE ALERT COULDN'T
HAVE COME

AT A MORE INCONVENIENT TIME.

SPYROS SENDS A TEAM
OF SURVEYORS TO INVESTIGATE

IF THE SETTLING EARTH

IS CALLING THE PLATFORM'S
ROOF PILLARS TO SINK.

♪♪

WE HAD SOME POINTS MOVING,
AND WE'RE DOUBLE CHECKING TO SEE

IF THEY CONTINUE TO MOVE

OR IF THEY ARE STAYING
IN THE SAME LEVEL

BECAUSE THE TUNNEL
BORING MACHINE

IS RIGHT UNDERNEATH US HERE,

SO WE'LL DOUBLE CHECK
IF IT'S ALL RIGHT.

A LOT OF THINGS
COULD HAPPEN HERE.

THERE'S A VERY BIG ARCH OVER US,

SO IF SOMETHING HAPPENS
WITH SOME OF THE PILLARS HERE,

IF PART OF THE TUNNEL
STARTS COLLAPSING

OR SOMETHING LIKE THIS,

WE WILL KNOW IT
BEFORE IT GETS CRITICAL.

Narrator: THEY CHECK ALL 60
PRISMS IN THE STATION,

DODGING COMMUTERS WHO ARE
OBLIVIOUS TO THE MASSIVE MACHINE

PASSING RIGHT
BENEATH THEIR FEET.

SOME DAYS I CAN ACTUALLY FEEL
THE BORING MACHINE

MOVING UNDER MY FEET,
LIKE, VIBRATING THE GROUND.

♪♪

I WILL TRANSFER
THE CALCULATIONS FROM TODAY.

WE CAN THEN SEE
WHAT WAS MEASURED,

AND THE TWO POINTS
THAT WE MEASURED

THAT WAS CLOSE
TO THE ALARM LEVELS

ARE ABOUT THE SAME HEIGHT
THAT THEY WERE LAST TIME.

SO THEY STOPPED MOVING DOWN.

EVERYTHING IS STABLE,

AND EVERYTHING IS WHERE
IT'S SUPPOSED TO BE.

Narrator: THE DATA CONFIRMS THAT
THE GROUND HAS STOPPED MOVING,

AT LEAST FOR NOW.

♪♪

SO THE TUNNELERS ARE CLEAR
TO PRESS ON WITH THE LAST

PUSH TOWARDS THE FINISHING LINE,

AND THE FINAL BREAKTHROUGH
INTO THE NEW CITYRINGEN STATION.

Man: I THINK WE SHOULD HAVE THEM
AT THIS POINT HERE

RATHER THAN THE BOTTOM LEVEL.

IN MY OPINION,
IT'S A BIT TOO CLOSE.

SO WE HAVE THAT LITTLE BIT
MORE EXTRA SPACE.

Narrator: HUNDREDS OF VIPs
AND OFFICIALS

ARE DUE TO ARRIVE TO WITNESS
THIS MOMENTOUS EVENT.

PAUL CAN'T AFFORD
ANYTHING TO GO WRONG.

SO TOMORROW EVERYTHING IS GOING
TO BE NICE AND CLEAN

AND READY FOR
THE FINAL BREAKTHROUGH.

OKAY.
I HAVE NO PROBLEMS.

Narrator: THE TEAM HAS ENLISTED
SOME EXTRA SPECIAL HELP

TO MAKE SURE THE FINAL
BREAKTHROUGH GOES OFF

WITHOUT A HITCH.

Evans: THAT'S A STATUE
OF THE SANTA BARBARA.

SHE'S THE PATRON SAINT
OF MINERS.

SO WHEREVER WE GO, WE WOULD LIKE
TO HAVE THE STATUE THERE

AS A GOOD LUCK SYMBOL
FOR OUR MINING,

TO KEEP US SAFE WHEREVER
WE MAY BE UNDERGROUND.

SHE'S BROUGHT US LUCK
ALL THIS WAY,

SO WHY SHOULDN'T SHE BRING US
LUCK FOR THE FINAL BREAKTHROUGH?

♪♪

Narrator: AFTER THREE YEARS OF
CONSTRUCTION WORK,

THE DAY OF THE FINAL TUNNELING
BREAKTHROUGH FINALLY ARRIVES.

EVERYTHING HAS BEEN LEADING UP
TO THIS CRUCIAL EVENT.

THE FINAL ACT, TODAY IS THE END,

AT LEAST OF
THE TUNNELING OPERATION.

Evans: WE'RE ALL READY.
WE'RE ALL SET UP, READY TO GO.

WE'RE JUST WAITING FOR THE LAST
OF THE VISITORS

AND GUESTS TO ARRIVE,

AND THEN WE'LL GET
THE ALL CLEAR,

AND WE'LL BE READY TO PUSH.

Narrator: IN COPENHAGEN,
ENGINEERS ARE COMING UPON

THE FINAL STAGES OF COMPLETING
THE $3.5 BILLION CITYRINGEN.

THE LAST MAJOR MILESTONE
IS BREAKING DOWN THE WALLS

BENEATH THE CITY'S
HISTORIC CENTRAL STATION.

WITH A SUBTERRANEAN FEAST
COMPLETE WITH CHAMPAGNE

AND RED CARPET ALL LAID OUT,

THE PRESSURE GROWS
ON THE TUNNELING TEAM.

THERE'S A BIG BUZZ IN THE AIR,

AND EVERYONE IS EXCITED
TO SEE THIS HAPPEN.

WELCOME TO THE LAST BREAK
IN OF THE PROJECT.

WE'RE GOING TO GO THROUGH
A COUPLE OF SAFETY ISSUES.

Narrator:
INSIDE THE TUNNELING MACHINE,

SYBIL YENSEN GEARS UP
FOR THE FINAL PUSH.

SYBIL, SYBIL, THIS IS PAUL.

RADIO CHECK, OVER.

HEY, PAUL.
THIS IS SYBIL AND TBM-4.

WE CAN HEAR YOU LOUD AND CLEAR.

OKAY, GOOD. EVERYTHING LOOKING
GOOD YOUR SIDE?

YES. WE CHECKED THE PUMPS.
EVERYTHING IS READY.

THANK YOU SO MUCH.

EVERYTHING IS GOOD TO GO
ON THEIR SIDE.

EVERYTHING IS HOW IT SHOULD BE.

LET'S GO.

STARTING TO ROLL NOW.

OKAY.
WE CAN START PUSHING NOW.

WE'LL START.

[ FOREIGN ]

♪♪

♪♪

Narrator:
WITH ONE FINAL NUDGE...

19 MILES OF CITYRINGEN
TUNNELS ARE COMPLETE,

AND THE 17 NEW STATIONS
FINALLY CONNECT.

WOO!

Narrator: FOR VALERIO, PAUL,
AND THE WHOLE TEAM,

IT'S THE END OF AN EXTRAORDINARY
UNDERGROUND JOURNEY.

BRILLIANT, FANTASTIC,
EXTREMELY HAPPY.

FOR COPENHAGEN, IT MEANS
THAT YOU CAN WALK FROM HERE

ALL AROUND TOWN

AND COME BACK
FROM THAT DIRECTION.

IT'S THE FIRST BIG,

HUGE STEP TOWARDS
THE COMPLETION OF THE METRO.

IT'S BEEN A MASSIVE ACHIEVEMENT
FOR EVERYBODY INVOLVED.

EVERYBODY IS SO HAPPY.

NOW TODAY IS JUST CELEBRATION.

THEY ARE JUST CELEBRATING
WHAT THEY DID.

Narrator: BUT JUST ONE FINAL
BREAKTHROUGH REMAINS

TO MARK THIS HUGE ACHIEVEMENT.

WOO-HOO!

[ FOREIGN ]

HAVE YOU SEEN THIS CAKE?

[ CHEERING ]

♪♪

Narrator: THE LAST TUNNELING
BREAKTHROUGH

MARKS A KEY MILESTONE
IN THIS AMBITIOUS

$3.5 BILLION PROJECT.

ALL THE MAJOR CIVIL ENGINEERING
WORK IS NOW COMPLETE.

THE TEAM HAS POURED MORE THAN
ONE MILLION TONS OF CONCRETE...

EXCAVATED MORE THAN
3 MILLION TONS OF EARTH,

AND INSTALLED 135,000
TUNNEL SEGMENTS.

WE'VE DONE OUR JOB,
AND WE'VE DONE IT VERY WELL.

Man: IT'S HUGE.
IT'S VERY BIG.

I REALLY NEED TO TAKE TIME
TO PROCESS IT.

Narrator:
OVER THE COMING MONTHS,

THE COPENHAGEN METRO TEAM

WILL CONTINUE TO LAY
THE LAST SECTIONS OF TRACK,

INSTALL THE STATIONS
SO THE TICKET HALLS CAN OPEN

AND PREPARE THE 39 TRAINS
FOR OPERATION.

Man: WHEN THIS IS ALL FINISHED,
I WANT TO COME BACK

AND TAKE THE FIRST
RIDE ON THE METRO.

I'M DEFINITELY GOING TO DO THAT.

Narrator: CITYRINGEN WILL SOON
EASE THE PRESSURE

ON COPENHAGEN'S ROADS

AND HELP KEEP THIS
HISTORIC CAPITAL CITY

RUNNING WELL INTO
THE NEXT CENTURY.