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These are the user uploaded subtitles that are being translated: 1 00:00:01,802 --> 00:00:03,402 Narrator: In norway... 2 00:00:03,404 --> 00:00:04,503 Man: Halt! 3 00:00:04,505 --> 00:00:06,171 Narrator: ...This team of engineers 4 00:00:06,173 --> 00:00:08,273 Is embarking on an epic endeavor. 5 00:00:08,275 --> 00:00:10,009 -Look up. -Yes. 6 00:00:10,011 --> 00:00:12,378 They're building a record-breaking ship 7 00:00:12,380 --> 00:00:16,915 That can slice through up to 1 1/2 feet of thick polar ice 8 00:00:16,917 --> 00:00:20,319 To explore the brutal arctic and antarctic oceans... 9 00:00:20,321 --> 00:00:23,489 It's the most advanced research vessel in the world. 10 00:00:23,491 --> 00:00:27,059 Narrator: ...Constructed from 12,500 tons of steel 11 00:00:27,061 --> 00:00:31,096 And equipped with a special reinforced hull. 12 00:00:31,098 --> 00:00:36,068 To build this colossus, the team must battle extreme winds... 13 00:00:36,070 --> 00:00:39,905 The weather, as you can see, it's not on our side. 14 00:00:39,907 --> 00:00:41,840 Narrator: ...And arctic temperatures. 15 00:00:41,842 --> 00:00:45,277 If it goes really bad, the whole thing can just explode. 16 00:00:45,279 --> 00:00:48,013 ♪ 17 00:00:48,015 --> 00:00:49,948 Narrator: This ice-busting ship 18 00:00:49,950 --> 00:00:53,819 Ranks in a league of ambitious new engineering wonders 19 00:00:53,821 --> 00:00:57,356 That are bigger, faster, taller, 20 00:00:57,358 --> 00:01:02,027 And more advanced than anything ever constructed before. 21 00:01:02,029 --> 00:01:05,898 This is the inside story of the extraordinary challenge 22 00:01:05,900 --> 00:01:08,367 Of building these giants. 23 00:01:08,369 --> 00:01:14,473 ♪ 24 00:01:14,475 --> 00:01:17,476 -- Captions by vitac -- www.Vitac.Com 25 00:01:17,478 --> 00:01:20,479 Captions paid for by discovery communications 26 00:01:20,481 --> 00:01:23,582 The oceans around the north and south poles 27 00:01:23,584 --> 00:01:26,552 Are some of the most dangerous in the world, 28 00:01:26,554 --> 00:01:28,454 With deadly icebergs, 29 00:01:28,456 --> 00:01:30,856 Ferocious storms, 30 00:01:30,858 --> 00:01:33,792 And bone-chilling temperatures. 31 00:01:33,794 --> 00:01:35,794 The inaccessibility of these waters 32 00:01:35,796 --> 00:01:40,165 Means that they harbor many mysteries for scientists, 33 00:01:40,167 --> 00:01:43,669 From the significant effects of the melting ice caps 34 00:01:43,671 --> 00:01:47,172 To the impact of plastic on wildlife in the ocean. 35 00:01:49,477 --> 00:01:53,145 Today, this team of engineers in norway is gearing up 36 00:01:53,147 --> 00:01:56,315 To construct a pioneering, globe-trotting vessel 37 00:01:56,317 --> 00:01:59,918 To help scientists investigate these polar mysteries. 38 00:01:59,920 --> 00:02:01,653 They're on a mission to construct 39 00:02:01,655 --> 00:02:03,622 An ice-slicing super ship, 40 00:02:03,624 --> 00:02:08,527 Capable of transporting teams of 56 researchers, 34 crew, 41 00:02:08,529 --> 00:02:10,796 And 100 tons of equipment 42 00:02:10,798 --> 00:02:13,332 Deep into the heart of the ice-trapped poles 43 00:02:13,334 --> 00:02:14,533 To undertake a series 44 00:02:14,535 --> 00:02:19,171 Of groundbreaking scientific experiments. 45 00:02:19,173 --> 00:02:22,307 Nina jenson is at the helm. 46 00:02:22,309 --> 00:02:25,210 So, the name of the vessel will be rev ocean, 47 00:02:25,212 --> 00:02:29,414 The r-e-v standing for research expedition vessel. 48 00:02:29,416 --> 00:02:32,050 In many ways, it's four ships in one. 49 00:02:32,052 --> 00:02:35,387 It's the most advanced research vessel in the world. 50 00:02:35,389 --> 00:02:37,289 It's an expedition ship. 51 00:02:37,291 --> 00:02:39,625 It's also a super yacht. 52 00:02:39,627 --> 00:02:42,361 And it has advanced trawling equipment 53 00:02:42,363 --> 00:02:45,430 To do sampling at great depths. 54 00:02:45,432 --> 00:02:47,599 ♪ 55 00:02:47,601 --> 00:02:51,737 This high-tech super ship will tower 10 decks high, 56 00:02:51,739 --> 00:02:56,141 72 feet wide, and 600 feet long, 57 00:02:56,143 --> 00:02:59,411 Making it the biggest research vessel in the world. 58 00:02:59,413 --> 00:03:01,580 ♪ 59 00:03:01,582 --> 00:03:04,483 Its reinforced swordfish-shaped snout 60 00:03:04,485 --> 00:03:10,656 Will slice through up to 1 1/2 feet of thick polar ice. 61 00:03:10,658 --> 00:03:14,326 Underneath, a special hatch, called a moon pool, 62 00:03:14,328 --> 00:03:19,131 Gives scientists inside direct access to the waters below, 63 00:03:19,133 --> 00:03:20,999 While vast hangars will house 64 00:03:21,001 --> 00:03:23,235 Three underwater research vehicles 65 00:03:23,237 --> 00:03:25,537 And a fast, rigid inflatable boat 66 00:03:25,539 --> 00:03:29,174 To transport scientists onto floating ice caps. 67 00:03:29,176 --> 00:03:30,475 This high-tech equipment 68 00:03:30,477 --> 00:03:34,680 Will launch through five huge hatch doors in the hull. 69 00:03:34,682 --> 00:03:36,982 On the main deck, as well as a helipad 70 00:03:36,984 --> 00:03:38,917 And on-board helicopter, 71 00:03:38,919 --> 00:03:43,622 A custom-built crane will hoist containers of supplies onboard 72 00:03:43,624 --> 00:03:48,760 So the crew can sail unsupported for three months straight. 73 00:03:48,762 --> 00:03:52,297 Up top, luxurious communal spaces give crews 74 00:03:52,299 --> 00:03:56,368 And scientists respite from deep-sea sampling, 75 00:03:56,370 --> 00:03:58,837 While an innovative computer-controlled bridge 76 00:03:58,839 --> 00:04:03,242 And navigation system keep the crew from getting lost at sea, 77 00:04:03,244 --> 00:04:06,612 Wherever they're traveling on the planet. 78 00:04:06,614 --> 00:04:09,915 No one has ever built a ship like this before 79 00:04:09,917 --> 00:04:12,451 That can navigate through hull-crushing ice 80 00:04:12,453 --> 00:04:15,487 While conducting a range of scientific studies, 81 00:04:15,489 --> 00:04:20,158 From examining marine life to polluted polar waters, 82 00:04:20,160 --> 00:04:21,994 So designing and constructing it 83 00:04:21,996 --> 00:04:24,730 Will be a major engineering challenge. 84 00:04:24,732 --> 00:04:27,466 Jenson: Obviously, making a vessel like this requires 85 00:04:27,468 --> 00:04:30,035 Someone with very unique capabilities 86 00:04:30,037 --> 00:04:33,605 To be able to design it and put everything together. 87 00:04:33,607 --> 00:04:37,743 ♪ 88 00:04:37,745 --> 00:04:40,912 Narrator: Nina and the team work with espen oeino, 89 00:04:40,914 --> 00:04:44,449 One of the world's most experienced naval architects, 90 00:04:44,451 --> 00:04:46,618 To draw up the blueprint for the ship. 91 00:04:46,620 --> 00:04:48,720 ♪ 92 00:04:48,722 --> 00:04:51,356 The sheer size of it is daunting, 93 00:04:51,358 --> 00:04:53,392 And although we have designed 94 00:04:53,394 --> 00:04:55,927 What is generally considered to be the largest yacht 95 00:04:55,929 --> 00:04:58,196 In the world in terms of tonnage, 96 00:04:58,198 --> 00:05:02,768 Here in this office, this will be bigger. 97 00:05:02,770 --> 00:05:06,738 Narrator: Espen and his team use the latest computer technology 98 00:05:06,740 --> 00:05:10,642 To design every single aspect of the ship. 99 00:05:10,644 --> 00:05:13,645 I think the most challenging thing about designing 100 00:05:13,647 --> 00:05:16,214 And building this ship is the sheer size. 101 00:05:16,216 --> 00:05:19,151 You have to be able to withstand a certain amount of ice. 102 00:05:19,153 --> 00:05:20,986 You have to have two helipads. 103 00:05:20,988 --> 00:05:23,855 You have to provide a rescue in case one helicopter goes down. 104 00:05:23,857 --> 00:05:25,357 There are many aspects like this 105 00:05:25,359 --> 00:05:28,360 That are specific to polar operations. 106 00:05:28,362 --> 00:05:30,495 It's quite daunting. 107 00:05:30,497 --> 00:05:34,266 Narrator: Work on the vessel begins in a shipyard in romania. 108 00:05:34,268 --> 00:05:38,337 Here, workers will use 12,500 tons of steel 109 00:05:38,339 --> 00:05:43,041 To build the ship's hull in six sections called blocks. 110 00:05:43,043 --> 00:05:47,879 They then position these in a huge dry dock 111 00:05:47,881 --> 00:05:50,082 Where welders fuse the blocks together 112 00:05:50,084 --> 00:05:52,150 To form the body of the vessel. 113 00:05:54,188 --> 00:05:57,022 Workers launch the ship into the water 114 00:05:57,024 --> 00:06:01,059 Then use a tug boat to tow the hull 3,000 miles 115 00:06:01,061 --> 00:06:03,829 To a second shipyard in northern norway. 116 00:06:03,831 --> 00:06:06,565 ♪ 117 00:06:06,567 --> 00:06:10,335 Here, a team of specialists will complete the ship 118 00:06:10,337 --> 00:06:14,539 By placing access doors in the hull, 119 00:06:14,541 --> 00:06:19,511 Positioning more than 350 windows, 120 00:06:19,513 --> 00:06:23,448 And installing the expedition equipment, 121 00:06:23,450 --> 00:06:26,118 Making this mega ice ship 122 00:06:26,120 --> 00:06:29,321 Ready to tackle the toughest seas on the planet. 123 00:06:29,323 --> 00:06:31,656 ♪ 124 00:06:31,658 --> 00:06:33,859 Work on the ship begins here, 125 00:06:33,861 --> 00:06:36,528 On the shores of the mighty danube river 126 00:06:36,530 --> 00:06:40,966 In tulcea, romania, in February 2018. 127 00:06:40,968 --> 00:06:43,635 This 1,000-strong team of engineers 128 00:06:43,637 --> 00:06:45,670 Begins the monumental task 129 00:06:45,672 --> 00:06:49,708 Of constructing this mega ice ship. 130 00:06:49,710 --> 00:06:51,376 They now have just two years 131 00:06:51,378 --> 00:06:56,148 To make this record-breaking vessel seaworthy. 132 00:06:56,150 --> 00:06:58,850 The man in charge of the build on the ground 133 00:06:58,852 --> 00:07:03,488 Is seasoned project manager aage linningsvoll. 134 00:07:03,490 --> 00:07:05,624 While the ship is under construction, 135 00:07:05,626 --> 00:07:08,960 Aage goes wherever it goes. 136 00:07:22,342 --> 00:07:26,211 Inside this huge warehouse, aage's team of metalworkers 137 00:07:26,213 --> 00:07:29,414 Weld together huge sheets of steel and girders 138 00:07:29,416 --> 00:07:32,918 To form large sections of the ship's hull. 139 00:07:32,920 --> 00:07:35,187 These pieces are called blocks. 140 00:07:47,100 --> 00:07:49,835 Each block weighs up to 1,000 tons 141 00:07:49,837 --> 00:07:53,371 And takes dozens of workers five months to build. 142 00:07:53,373 --> 00:07:57,242 ♪ 143 00:07:57,244 --> 00:08:00,245 When complete, they mount the blocks on rails 144 00:08:00,247 --> 00:08:03,715 And use backhoes to push them to the dock. 145 00:08:03,717 --> 00:08:05,884 Here, they weld the blocks together 146 00:08:05,886 --> 00:08:09,054 To form the ship's hull. 147 00:08:09,056 --> 00:08:13,291 In the dock, they also install the ship's 8-ton propeller 148 00:08:13,293 --> 00:08:18,864 And four 43-ton diesel electric engines. 149 00:08:18,866 --> 00:08:21,366 Once assembled, the hull must be tough enough 150 00:08:21,368 --> 00:08:24,002 To withstand brutal brutal arctic conditions 151 00:08:24,004 --> 00:08:28,173 And slice through up to 1 1/2 feet of ice. 152 00:08:28,175 --> 00:08:30,141 But what's unique about this ship 153 00:08:30,143 --> 00:08:33,912 Is that its design calls for it to be full of holes. 154 00:08:45,893 --> 00:08:48,793 The team make the ship's 600-foot-long hull 155 00:08:48,795 --> 00:08:52,130 Out of 12,500 tons of steel, 156 00:08:52,132 --> 00:08:56,468 Building it up out of pre-made sections 10 decks high. 157 00:08:56,470 --> 00:08:58,236 The hull must be strong enough 158 00:08:58,238 --> 00:09:01,773 To cope with the ferocious polar seas, 159 00:09:01,775 --> 00:09:04,242 But it must also contain several openings 160 00:09:04,244 --> 00:09:07,012 Unique to research vessels. 161 00:09:07,014 --> 00:09:09,447 There are five massive doors in the sides 162 00:09:09,449 --> 00:09:11,950 To launch the ship's scientific boats. 163 00:09:11,952 --> 00:09:14,286 ♪ 164 00:09:14,288 --> 00:09:18,356 Underneath, the 16x23-foot moon pool hatch 165 00:09:18,358 --> 00:09:23,495 Gives sub-sea vehicles easy access to the deep sea, 166 00:09:23,497 --> 00:09:27,399 And inside, there are cavernous hangars for the helicopter, 167 00:09:29,436 --> 00:09:31,636 Science lab, 168 00:09:31,638 --> 00:09:33,738 And trawler system. 169 00:09:33,740 --> 00:09:35,173 To solve this problem, 170 00:09:35,175 --> 00:09:40,779 Engineers must install 1,675 super-strong steel beams 171 00:09:40,781 --> 00:09:43,782 At specific locations within the hull. 172 00:09:43,784 --> 00:09:46,551 The extra beams should make the hull tough enough 173 00:09:46,553 --> 00:09:49,854 To withstand the extreme forces of the polar seas. 174 00:09:58,799 --> 00:10:01,666 Installing each beam is a challenge. 175 00:10:01,668 --> 00:10:03,735 They must be perfectly positioned, 176 00:10:03,737 --> 00:10:06,471 And each weld must be faultless 177 00:10:06,473 --> 00:10:08,974 Because the beams strengthen every opening, 178 00:10:08,976 --> 00:10:12,143 From the cavernous hangars to the numerous hatches. 179 00:10:14,715 --> 00:10:18,350 Aage must personally sign off these critical components 180 00:10:18,352 --> 00:10:21,820 Before they can move to the next stage of the build. 181 00:10:21,822 --> 00:10:27,826 Now we are almost finished, so now I want to have a quick look. 182 00:10:27,828 --> 00:10:29,494 Narrator: It takes two hours for aage 183 00:10:29,496 --> 00:10:33,365 To inspect every nook and cranny of the vessel. 184 00:10:33,367 --> 00:10:34,899 He must be certain 185 00:10:34,901 --> 00:10:38,136 That the reinforcements meet his high standards. 186 00:10:59,092 --> 00:11:01,292 [ sparks crackling ] 187 00:11:08,535 --> 00:11:10,335 Over the next six months, 188 00:11:10,337 --> 00:11:13,638 The team painstakingly build the rest of the hull, 189 00:11:13,640 --> 00:11:16,274 Welding the blocks together, 190 00:11:16,276 --> 00:11:18,510 Finishing the bulbous bow, 191 00:11:18,512 --> 00:11:20,645 And strengthening the main decks, 192 00:11:20,647 --> 00:11:24,349 To complete the steel shell of the ship. 193 00:11:24,351 --> 00:11:26,985 Now they face their next big challenge -- 194 00:11:26,987 --> 00:11:30,789 Towing the powerless ship 3,000 miles to norway 195 00:11:30,791 --> 00:11:34,859 So the second phase of this ambitious build can begin. 196 00:11:34,861 --> 00:11:38,897 ♪ 197 00:11:40,333 --> 00:11:44,436 ♪ 198 00:11:44,438 --> 00:11:46,871 Narrator: Over the last 18 months, 199 00:11:46,873 --> 00:11:50,208 This team of 1,000 steelworkers in romania 200 00:11:50,210 --> 00:11:52,410 Has assembled the steel shell 201 00:11:52,412 --> 00:11:57,882 For the world's largest ice-busting research vessel. 202 00:11:57,884 --> 00:12:00,985 Now this steely skeleton must undertake 203 00:12:00,987 --> 00:12:04,055 An epic 3,000-mile journey. 204 00:12:04,057 --> 00:12:06,958 It takes four weeks to tow the ship around europe 205 00:12:06,960 --> 00:12:09,561 And through the norwegian fjords 206 00:12:09,563 --> 00:12:14,566 To a second shipyard in brattvaag, norway. 207 00:12:14,568 --> 00:12:18,570 Here, they face the herculean challenge of completing the ship 208 00:12:18,572 --> 00:12:21,272 By installing the huge hatch doors, 209 00:12:21,274 --> 00:12:25,110 Windows, and crucial scientific equipment. 210 00:12:25,112 --> 00:12:27,345 This phase is happening during the winter, 211 00:12:27,347 --> 00:12:32,250 When temperatures in norway plummet to -22 degrees. 212 00:12:32,252 --> 00:12:37,222 This will make the next stage of the build even more difficult. 213 00:12:37,224 --> 00:12:41,760 Eager to see the ship's arrival is project manager aage. 214 00:12:41,762 --> 00:12:44,028 Linningsvoll: We are here at the yard in norway. 215 00:12:44,030 --> 00:12:48,233 We are here now and waiting for the vessel. 216 00:12:48,235 --> 00:12:51,102 Narrator: Aage is relieved to see the ship has survived 217 00:12:51,104 --> 00:12:54,272 Its arduous 3,000-mile trip around europe 218 00:12:54,274 --> 00:12:56,174 In pristine condition. 219 00:12:56,176 --> 00:13:01,679 It's very exciting now to see that the vessel is coming here 220 00:13:01,681 --> 00:13:07,218 To the outfitting yard, and without any damages. 221 00:13:07,220 --> 00:13:10,588 We have a lot of challenges and work ahead of us. 222 00:13:15,762 --> 00:13:18,096 Narrator: Aage and the team have just six months 223 00:13:18,098 --> 00:13:20,665 To transform this steel shell 224 00:13:20,667 --> 00:13:24,836 Into the world's largest ice-slicing research vessel. 225 00:13:24,838 --> 00:13:27,505 Their first challenge is to install one of the ship's 226 00:13:27,507 --> 00:13:29,941 Major expedition components -- 227 00:13:29,943 --> 00:13:32,811 The custom-built knuckle crane. 228 00:13:32,813 --> 00:13:35,480 Oeino: The crane is an important part of the vessel 229 00:13:35,482 --> 00:13:39,417 Because when you're in antarctica or in arctic areas, 230 00:13:39,419 --> 00:13:43,454 You may not have any shore-side support in terms of cranes, 231 00:13:43,456 --> 00:13:46,724 So lifting containers onto the ice or from the ice 232 00:13:46,726 --> 00:13:50,361 Back onto the vessel will be done by this crane. 233 00:13:50,363 --> 00:13:53,998 Narrator: This crane, capable of lifting 33-ton containers 234 00:13:54,000 --> 00:13:57,836 Filled with food, mobile labs, and science equipment, 235 00:13:57,838 --> 00:13:59,971 Is not just functional. 236 00:13:59,973 --> 00:14:02,340 Most cranes are not designed to look nice, 237 00:14:02,342 --> 00:14:06,110 But we thought that, given its prominent position onboard, 238 00:14:06,112 --> 00:14:08,479 We should make it look as nice and fitting to 239 00:14:08,481 --> 00:14:10,048 The vessel as possible. 240 00:14:10,050 --> 00:14:14,752 ♪ 241 00:14:14,754 --> 00:14:17,655 Narrator: This innovative crane is unique to this vessel 242 00:14:17,657 --> 00:14:22,193 And weighs a staggering 66 tons. 243 00:14:22,195 --> 00:14:23,795 It will be used to load 244 00:14:23,797 --> 00:14:27,932 And unload containers of supplies and equipment 245 00:14:27,934 --> 00:14:30,869 So the ship and crew can operate unsupported 246 00:14:30,871 --> 00:14:36,007 In the polar regions for up to 90 days. 247 00:14:36,009 --> 00:14:38,243 Yet this is no ordinary crane. 248 00:14:40,447 --> 00:14:44,782 When at sea, special sensors and an autonomous control system 249 00:14:44,784 --> 00:14:47,619 Precisely counteract the motion of the waves, 250 00:14:47,621 --> 00:14:49,954 Even in the roughest conditions. 251 00:14:52,259 --> 00:14:54,993 Now the crane's load stays steady, 252 00:14:54,995 --> 00:14:58,229 Even if the ship begins to roll. 253 00:14:58,231 --> 00:14:59,898 And thanks to a central joint 254 00:14:59,900 --> 00:15:03,001 And prototype streamlined design, 255 00:15:03,003 --> 00:15:08,239 It simply folds away once its work is complete. 256 00:15:08,241 --> 00:15:09,607 Halt! 257 00:15:09,609 --> 00:15:14,178 We have been waiting quite a long time for the crane, yeah. 258 00:15:14,180 --> 00:15:18,416 It's exciting to get the crane onboard. 259 00:15:18,418 --> 00:15:20,718 Narrator: In frigid winter conditions, 260 00:15:20,720 --> 00:15:22,687 The team faces the difficult task 261 00:15:22,689 --> 00:15:25,590 Of hauling this 66-ton crane 262 00:15:25,592 --> 00:15:27,692 From the barge that it arrived on 263 00:15:27,694 --> 00:15:30,128 To the ship. 264 00:15:30,130 --> 00:15:34,432 Once on the vessel, the team must perfectly line up 84 bolts 265 00:15:34,434 --> 00:15:38,336 At the base of the crane to secure it to this pedestal. 266 00:15:47,047 --> 00:15:49,180 Lifting this massive crane 267 00:15:49,182 --> 00:15:51,416 During the peak of norwegian winter 268 00:15:51,418 --> 00:15:53,384 Is a high-risk operation. 269 00:15:53,386 --> 00:15:55,753 It's the wind that you can lose control, 270 00:15:55,755 --> 00:16:00,291 By the crane start swinging in the wind. 271 00:16:00,293 --> 00:16:02,293 Look up! 272 00:16:02,295 --> 00:16:05,396 Narrator: Aage's team must use two yard cranes, 273 00:16:05,398 --> 00:16:08,132 One attached to either end of the ship's crane, 274 00:16:08,134 --> 00:16:11,035 To undertake this herculean lift. 275 00:16:11,037 --> 00:16:14,238 The cranes have to work in perfect unison 276 00:16:14,240 --> 00:16:16,574 For this to be a success. 277 00:16:16,576 --> 00:16:18,710 Linningsvoll: This is a prototype crane, 278 00:16:18,712 --> 00:16:20,945 Especially designed for the vessel, 279 00:16:20,947 --> 00:16:22,914 So it is very important 280 00:16:22,916 --> 00:16:27,151 That everything going according to plan. 281 00:16:27,153 --> 00:16:31,155 Narrator: As the crane dangles precariously over the main deck, 282 00:16:31,157 --> 00:16:33,858 The weather takes a turn for the worse. 283 00:16:33,860 --> 00:16:37,261 ♪ 284 00:16:37,263 --> 00:16:41,632 The weather, as you can see, it's not on our side. 285 00:16:41,634 --> 00:16:45,336 Narrator: The team fights the driving rain and presses on. 286 00:16:47,407 --> 00:16:49,173 It's a struggle, 287 00:16:49,175 --> 00:16:53,711 But they raise the crane into position over the deck. 288 00:16:53,713 --> 00:16:55,980 Now comes the tricky part. 289 00:17:03,423 --> 00:17:05,623 [ speaking indistinctly ] 290 00:17:18,238 --> 00:17:21,239 With the limited winter sunlight fading, 291 00:17:21,241 --> 00:17:25,309 The team braces to secure the crane to its base. 292 00:17:33,953 --> 00:17:37,555 They slowly lower the crane, inch by inch, 293 00:17:37,557 --> 00:17:39,524 Down into the bolt holes. 294 00:17:42,362 --> 00:17:43,594 [ metal clangs ] 295 00:17:43,596 --> 00:17:46,764 Finally, it slides into position. 296 00:17:46,766 --> 00:17:49,067 They've done it. 297 00:18:02,615 --> 00:18:04,615 [ thunder rumbles ] 298 00:18:04,617 --> 00:18:09,921 ♪ 299 00:18:09,923 --> 00:18:11,656 Over the next few weeks, 300 00:18:11,658 --> 00:18:16,027 An army of specialists swarms over every part of the vessel. 301 00:18:16,029 --> 00:18:19,997 They install wiring, pipework, and ventilation, 302 00:18:19,999 --> 00:18:22,433 All working to turn this steel shell 303 00:18:22,435 --> 00:18:25,837 Into a high-tech, operational ship, 304 00:18:25,839 --> 00:18:28,406 But now they face the difficult task 305 00:18:28,408 --> 00:18:32,777 Of filling a 72x16-foot hole in the side of the hull 306 00:18:32,779 --> 00:18:36,814 That houses the ship's one-of-a-kind sub-sea vessels. 307 00:18:36,816 --> 00:18:40,284 ♪ 308 00:18:41,888 --> 00:18:47,558 ♪ 309 00:18:47,560 --> 00:18:49,393 Narrator: In norway, the team building 310 00:18:49,395 --> 00:18:51,996 The largest research vessel in the world 311 00:18:51,998 --> 00:18:55,266 Has reached a crucial stage of the build 312 00:18:55,268 --> 00:19:00,371 And now faces their biggest challenge yet. 313 00:19:00,373 --> 00:19:03,541 Chief engineer trond kjersem is in charge of 314 00:19:03,543 --> 00:19:06,611 One of the ship's most critical systems of all... 315 00:19:06,613 --> 00:19:07,712 Hello. 316 00:19:07,714 --> 00:19:09,046 ...The hydraulics. 317 00:19:09,048 --> 00:19:11,282 On a vessel like this, we have all sorts of systems, 318 00:19:11,284 --> 00:19:14,919 Large and small, and no matter how small 319 00:19:14,921 --> 00:19:16,487 Or large they are, you need to check them, 320 00:19:16,489 --> 00:19:20,158 That they are okay and working as they should. 321 00:19:20,160 --> 00:19:22,560 Narrator: The hydraulic system is a network of pipes 322 00:19:22,562 --> 00:19:24,929 Filled with a special fluid 323 00:19:24,931 --> 00:19:29,033 That is responsible for moving the rudder left and right, 324 00:19:29,035 --> 00:19:32,770 Opening the hatch doors, and controlling the crane. 325 00:19:32,772 --> 00:19:35,406 Kjersem: Hydraulics are used for many different operations. 326 00:19:35,408 --> 00:19:37,308 A ship today would not function 327 00:19:37,310 --> 00:19:41,979 Without proper hydraulic systems. 328 00:19:41,981 --> 00:19:45,216 Narrator: It is vital the ship's endless network of pipes 329 00:19:45,218 --> 00:19:47,451 Is able to withstand the extreme forces 330 00:19:47,453 --> 00:19:50,254 Exerted by the hydraulic system. 331 00:19:50,256 --> 00:19:53,958 The only way to test the pipes is to crank up the pressure 332 00:19:53,960 --> 00:19:57,762 Then check every single joint by hand. 333 00:19:57,764 --> 00:20:00,698 Kjersem: We will bring up the hydraulic pressure 334 00:20:00,700 --> 00:20:03,367 To above working pressure 335 00:20:03,369 --> 00:20:06,003 To stress the lines and the couplings, 336 00:20:06,005 --> 00:20:08,139 So that means climbing up on scaffolding, 337 00:20:08,141 --> 00:20:10,575 Down in confined spaces, 338 00:20:10,577 --> 00:20:14,212 And yeah, you know, so it's a little bit challenging, 339 00:20:14,214 --> 00:20:17,148 But that's what we like. 340 00:20:17,150 --> 00:20:19,817 Narrator: The pressure in the pipes reaches a staggering 341 00:20:19,819 --> 00:20:23,487 4,600 pounds per square inch. 342 00:20:23,489 --> 00:20:26,624 It's very important that the piping and the piping systems 343 00:20:26,626 --> 00:20:29,860 Are correctly done and clean. 344 00:20:29,862 --> 00:20:33,664 If not, that can cause serious damages 345 00:20:33,666 --> 00:20:37,168 And even injuries to people. 346 00:20:37,170 --> 00:20:39,036 Narrator: Over the following hour, 347 00:20:39,038 --> 00:20:41,872 Trond weaves his way through the entire ship. 348 00:20:41,874 --> 00:20:44,976 It's a lot of pipes. It's a big job, huh? 349 00:20:44,978 --> 00:20:46,277 Man: Yeah. 350 00:20:46,279 --> 00:20:49,447 Narrator: He inspects every connection along the way, 351 00:20:49,449 --> 00:20:51,782 Searching for signs of hydraulic oil 352 00:20:51,784 --> 00:20:54,118 Leaking from the pipes. 353 00:20:54,120 --> 00:20:55,686 Kjersem: Sometimes, it is a little bit strange, 354 00:20:55,688 --> 00:20:59,090 Because you don't remember names of all your relatives, 355 00:20:59,092 --> 00:21:02,593 But you remember the numbers of valves down in the engine room. 356 00:21:02,595 --> 00:21:04,395 [ laughs ] 357 00:21:04,397 --> 00:21:06,731 Narrator: But as the test nears the end, 358 00:21:06,733 --> 00:21:10,301 Something catches trond's eye. 359 00:21:10,303 --> 00:21:14,171 Kjersem: You see on the clamp, there, is some drop. 360 00:21:14,173 --> 00:21:17,308 Narrator: If the hydraulic pipes were to fail at sea, 361 00:21:17,310 --> 00:21:21,178 High-pressure jets of oil could seriously injure the crew. 362 00:21:21,180 --> 00:21:23,180 Kjersem: It's probably from the -- 363 00:21:23,182 --> 00:21:25,916 Maybe from the boost connection. Man: Ah! 364 00:21:25,918 --> 00:21:28,286 Narrator: Thankfully, it's a quick fix. 365 00:21:28,288 --> 00:21:33,357 A twist of the wrench, and the system is sealed. 366 00:21:33,359 --> 00:21:38,129 Luckily, it worked out fine, so thumbs up. 367 00:21:40,400 --> 00:21:42,767 Narrator: With the hydraulic system up and running, 368 00:21:42,769 --> 00:21:46,904 The team now faces their next big challenge. 369 00:21:46,906 --> 00:21:50,074 They must install one of the ship's biggest components -- 370 00:21:50,076 --> 00:21:54,879 Three 16-foot hatch doors, each weighing 8 tons. 371 00:21:54,881 --> 00:21:59,583 It's basically three doors on the port side of the vessel, 372 00:21:59,585 --> 00:22:03,287 And it's closing up what we call the hangar. 373 00:22:05,325 --> 00:22:07,391 Narrator: The ship will have two large openings 374 00:22:07,393 --> 00:22:10,027 On either side of the hull. 375 00:22:10,029 --> 00:22:13,164 These allow the crew to launch the ship's onboard submarine 376 00:22:13,166 --> 00:22:14,799 And research boats. 377 00:22:16,969 --> 00:22:19,370 The largest opening, on the port side, 378 00:22:19,372 --> 00:22:24,275 Measures 72 feet long and 16 feet high 379 00:22:24,277 --> 00:22:29,613 And needs to be filled by three 8-ton hatch doors. 380 00:22:29,615 --> 00:22:34,952 Craning these into position will be a fierce challenge. 381 00:22:34,954 --> 00:22:41,625 The team will work slowly and support the door with guy-lines. 382 00:22:41,627 --> 00:22:43,361 But a big gust of wind 383 00:22:43,363 --> 00:22:47,131 Could blow the door into the hull 384 00:22:47,133 --> 00:22:50,267 And cause serious damage. 385 00:22:50,269 --> 00:22:53,304 ♪ 386 00:23:05,351 --> 00:23:06,984 There are now just six weeks 387 00:23:06,986 --> 00:23:09,887 Until the ship must be seaworthy. 388 00:23:09,889 --> 00:23:12,623 Aage and the team are under intense pressure 389 00:23:12,625 --> 00:23:16,927 To install the three hatch doors in three days. 390 00:23:16,929 --> 00:23:21,198 Aage makes his own final checks for this difficult lift. 391 00:23:21,200 --> 00:23:25,836 It's very important that the lift go coming up controlled 392 00:23:25,838 --> 00:23:28,406 And gently. 393 00:23:28,408 --> 00:23:30,274 So cross the fingers. 394 00:23:30,276 --> 00:23:32,243 Narrator: The team begins the installation 395 00:23:32,245 --> 00:23:34,779 Of the first hatch door. 396 00:23:34,781 --> 00:23:36,380 And now it's ready to lift. 397 00:23:36,382 --> 00:23:42,753 ♪ 398 00:23:42,755 --> 00:23:45,990 Narrator: The crane operator guides the 8-ton hatch door 399 00:23:45,992 --> 00:23:47,725 Over the rear of the vessel. 400 00:23:53,866 --> 00:23:59,170 Aage heads onboard to oversee the tricky installation. 401 00:23:59,172 --> 00:24:00,704 Linningsvoll: Now it's looking good. 402 00:24:00,706 --> 00:24:02,573 The hatch is coming in now. 403 00:24:02,575 --> 00:24:05,910 Narrator: Now the team must precisely guide the hinges 404 00:24:05,912 --> 00:24:09,413 Into their housing and use bolts to secure them. 405 00:24:09,415 --> 00:24:11,148 Linningsvoll: It has to fit perfectly. 406 00:24:11,150 --> 00:24:14,185 If not, the water comes in on deck, here, 407 00:24:14,187 --> 00:24:16,654 And that is not good. 408 00:24:16,656 --> 00:24:18,456 Narrator: The team uses manual winches 409 00:24:18,458 --> 00:24:21,125 To raise the base of the hatch door 410 00:24:21,127 --> 00:24:23,828 So they can inch the door in at an angle. 411 00:24:23,830 --> 00:24:26,230 [ indistinct radio chatter ] 412 00:24:26,232 --> 00:24:29,099 After 20 minutes of minute adjustments, 413 00:24:29,101 --> 00:24:31,202 The door is in position. 414 00:24:41,647 --> 00:24:43,481 The team pushes the bolts through 415 00:24:43,483 --> 00:24:47,685 To secure the door into place. 416 00:24:47,687 --> 00:24:52,323 So, finally, the hatch is in position. 417 00:24:52,325 --> 00:24:57,895 It actually looks good, and the operation went smooth. 418 00:24:57,897 --> 00:24:59,964 The plan was to do one hatch per day, 419 00:24:59,966 --> 00:25:05,069 But I think I will try to do the second one. 420 00:25:05,071 --> 00:25:06,737 Narrator: With the first installation 421 00:25:06,739 --> 00:25:09,073 Running without a hitch, 422 00:25:09,075 --> 00:25:13,744 Aage decides to proceed with the second ahead of schedule. 423 00:25:13,746 --> 00:25:16,847 Looks like they are ready to lift the second hatch, 424 00:25:16,849 --> 00:25:22,553 And, hopefully, it will work out as smooth as the first one. 425 00:25:22,555 --> 00:25:25,890 Narrator: The lift goes according to plan, 426 00:25:25,892 --> 00:25:30,661 But just as they position the hinges, their luck runs out. 427 00:25:30,663 --> 00:25:33,264 The crane loses all power 428 00:25:33,266 --> 00:25:36,133 And leaves the door dangling precariously. 429 00:25:39,572 --> 00:25:43,207 To make matters worse, the tide is falling, 430 00:25:43,209 --> 00:25:46,110 And the ship is descending with it. 431 00:25:46,112 --> 00:25:49,480 This slowly drives the top edge of the hatch opening 432 00:25:49,482 --> 00:25:51,582 Down into the hanging door. 433 00:25:59,825 --> 00:26:04,261 ♪ 434 00:26:05,932 --> 00:26:08,866 ♪ 435 00:26:08,868 --> 00:26:10,901 Narrator: In brattvaag, norway, 436 00:26:10,903 --> 00:26:13,470 This team of engineers is racing to build 437 00:26:13,472 --> 00:26:17,841 The largest ice-busting polar research ship in the world. 438 00:26:17,843 --> 00:26:20,911 Project lead aage and his team are pushing to install 439 00:26:20,913 --> 00:26:24,882 Three 8-ton hatch doors in three days. 440 00:26:24,884 --> 00:26:27,484 It has to fit 100%. 441 00:26:27,486 --> 00:26:30,087 Narrator: But just as they attempt to fit the second hatch, 442 00:26:30,089 --> 00:26:32,823 Ahead of schedule, 443 00:26:32,825 --> 00:26:34,925 The crane loses all power. 444 00:26:37,663 --> 00:26:41,599 And, worse still, the tide is falling. 445 00:26:41,601 --> 00:26:44,201 With the yard's crane powerless, 446 00:26:44,203 --> 00:26:47,938 The position of the hatch door remains constant. 447 00:26:47,940 --> 00:26:52,710 But as the tide falls, so, too, does the ship. 448 00:26:52,712 --> 00:26:55,479 This forces the top of the hatch opening 449 00:26:55,481 --> 00:26:58,983 Down into the suspended door. 450 00:26:58,985 --> 00:27:01,952 If the team doesn't get the crane working soon, 451 00:27:01,954 --> 00:27:04,722 The sinking ship will drive the hatch hinges up 452 00:27:04,724 --> 00:27:09,827 Through their housing and rupture the steel hull. 453 00:27:14,667 --> 00:27:16,100 To buy some time, 454 00:27:16,102 --> 00:27:20,270 The team onboard uses manual winches called chainfalls 455 00:27:20,272 --> 00:27:23,340 To lower each corner of the door by hand. 456 00:27:39,659 --> 00:27:42,593 Over the next hour, the team works tirelessly, 457 00:27:42,595 --> 00:27:45,362 Slacking the chains in an attempt 458 00:27:45,364 --> 00:27:49,600 To lower the hatch door with the tide. 459 00:27:49,602 --> 00:27:54,938 With just inches to spare before the winches run out of chain, 460 00:27:54,940 --> 00:27:58,142 The crane kicks back into action. 461 00:27:58,144 --> 00:28:02,980 We got the message that the crane is back in operation, 462 00:28:02,982 --> 00:28:04,715 And that is very good. 463 00:28:04,717 --> 00:28:07,084 Narrator: With power restored to the crane, 464 00:28:07,086 --> 00:28:10,554 The team quickly bolts the second door in place. 465 00:28:12,525 --> 00:28:15,893 A day ahead of schedule, the team presses on with 466 00:28:15,895 --> 00:28:18,629 Lifting the third hatch door into position. 467 00:28:20,966 --> 00:28:22,433 It's coming in. 468 00:28:22,435 --> 00:28:25,035 Narrator: With the other hatches in position already, 469 00:28:25,037 --> 00:28:30,240 The real test now is to see if the last hatch fits. 470 00:28:30,242 --> 00:28:33,977 The problem is that if it has not been fit, 471 00:28:33,979 --> 00:28:36,780 Then we have the risk that we have to take 472 00:28:36,782 --> 00:28:41,785 All three hatches out again, and that will, of course, 473 00:28:41,787 --> 00:28:46,190 Cause delay due to extra work, money. 474 00:28:47,760 --> 00:28:49,493 Narrator: The moment of truth. 475 00:28:49,495 --> 00:28:52,496 [ indistinct shouting ] 476 00:28:52,498 --> 00:28:55,766 It slots in perfectly. 477 00:28:55,768 --> 00:28:59,970 Yeah, it looks like the hatch is in the correct position. 478 00:28:59,972 --> 00:29:04,775 Well, we are very happy now that everything went smooth. 479 00:29:04,777 --> 00:29:07,311 So this is very good. 480 00:29:07,313 --> 00:29:09,046 Narrator: With the doors in place, 481 00:29:09,048 --> 00:29:12,015 The hull is finally watertight. 482 00:29:12,017 --> 00:29:14,451 The team can begin painting the vast science 483 00:29:14,453 --> 00:29:16,186 And helicopter hangars. 484 00:29:16,188 --> 00:29:22,159 ♪ 485 00:29:22,161 --> 00:29:24,428 This record-breaking research vessel 486 00:29:24,430 --> 00:29:27,865 Will have enough cabins to accommodate 90 people 487 00:29:27,867 --> 00:29:31,635 On polar expeditions lasting up to 90 days, 488 00:29:31,637 --> 00:29:34,671 But the ship's crew will stay onboard for even longer. 489 00:29:34,673 --> 00:29:36,974 Baadnes: The crew is staying half the year 490 00:29:36,976 --> 00:29:38,442 Onboard this vessel, 491 00:29:38,444 --> 00:29:43,914 And, for us, it's basically our second home. 492 00:29:43,916 --> 00:29:46,517 Nils baadnes is the ship's captain 493 00:29:46,519 --> 00:29:49,820 And wants only the best for his crew. 494 00:29:49,822 --> 00:29:52,289 He makes a rare visit onto the ship 495 00:29:52,291 --> 00:29:56,326 To ensure the crew cabins are of the highest standard. 496 00:29:56,328 --> 00:29:59,096 Baadnes: Of course, we have passenger cabins 497 00:29:59,098 --> 00:30:00,597 And scientists' cabins, as well, 498 00:30:00,599 --> 00:30:04,001 But the crew are here for longer, 499 00:30:04,003 --> 00:30:07,938 So it's important to get the standard good. 500 00:30:07,940 --> 00:30:10,107 Narrator: And he is a harsh critic. 501 00:30:10,109 --> 00:30:13,310 I can see a little bit vibration here, 502 00:30:13,312 --> 00:30:15,946 So that has to be fastened. 503 00:30:15,948 --> 00:30:18,816 Narrator: These cabins will include soundproofing, 504 00:30:18,818 --> 00:30:20,818 Triple-glazed windows, 505 00:30:20,820 --> 00:30:24,855 Led lighting, and all the modern conveniences. 506 00:30:24,857 --> 00:30:28,392 Oh, this is the bathroom around here. 507 00:30:28,394 --> 00:30:31,028 There's still some installing to do. 508 00:30:31,030 --> 00:30:33,096 Narrator: With the inspection complete, 509 00:30:33,098 --> 00:30:35,566 Captain nils has concerns. 510 00:30:35,568 --> 00:30:39,303 There is still a lot of work to do. 511 00:30:39,305 --> 00:30:43,574 The ship has to be seaworthy in a short period in time, 512 00:30:43,576 --> 00:30:47,511 And they need to get this sorted. 513 00:30:47,513 --> 00:30:50,781 Narrator: With all hands on deck to get the cabins finished, 514 00:30:50,783 --> 00:30:53,650 The team's next challenge is even tougher -- 515 00:30:53,652 --> 00:30:56,119 Installing the captain's one-of-a-kind 516 00:30:56,121 --> 00:30:58,956 23-foot-long bridge deck window. 517 00:30:58,958 --> 00:31:02,259 ♪ 518 00:31:03,829 --> 00:31:07,331 ♪ 519 00:31:07,333 --> 00:31:10,801 Narrator: In brattvaag, norway, an army of engineers 520 00:31:10,803 --> 00:31:14,037 Is battling to construct an ice-busting research ship 521 00:31:14,039 --> 00:31:17,774 In the depths of winter, and workers are gearing up 522 00:31:17,776 --> 00:31:20,344 To begin the next stage of the build -- 523 00:31:20,346 --> 00:31:23,981 Installing the ship's 350 windows. 524 00:31:23,983 --> 00:31:27,985 Today, they will be fitting one of the largest panes of glass, 525 00:31:27,987 --> 00:31:32,556 The mammoth 23-foot-long bridge deck main window. 526 00:31:32,558 --> 00:31:35,659 Baadnes: They're preparing the window for lifting, 527 00:31:35,661 --> 00:31:39,463 So we've been waiting for this for quite a while now. 528 00:31:39,465 --> 00:31:43,233 This glass has been special-built for this ship. 529 00:31:43,235 --> 00:31:45,702 It takes months to produce this glass. 530 00:31:45,704 --> 00:31:51,041 It's a critical operation to install it. 531 00:31:51,043 --> 00:31:53,710 Narrator: The team must lift this 23-foot-long, 532 00:31:53,712 --> 00:31:57,547 1-ton, curved sheet of glass in one piece. 533 00:31:59,652 --> 00:32:03,120 To do that, a crane and a robotic suction mount 534 00:32:03,122 --> 00:32:06,156 Must work together. 535 00:32:06,158 --> 00:32:07,925 First, the robotic arm, 536 00:32:07,927 --> 00:32:11,094 Equipped with 16 suction plates made of rubber, 537 00:32:11,096 --> 00:32:13,997 Connects to the glass. 538 00:32:13,999 --> 00:32:17,100 Next, the crane lifts the robotic arm. 539 00:32:17,102 --> 00:32:19,136 [ mechanical whirring ] 540 00:32:21,440 --> 00:32:24,474 Workers then guide the window into its steel frame, 541 00:32:24,476 --> 00:32:27,177 89 feet above the hull's base line, 542 00:32:27,179 --> 00:32:29,246 With pinpoint accuracy. 543 00:32:32,418 --> 00:32:34,685 One wrong move, and the whole piece 544 00:32:34,687 --> 00:32:37,120 Could shatter against the ship's frame. 545 00:32:37,122 --> 00:32:39,122 [ glass shatters ] 546 00:32:41,293 --> 00:32:43,827 Baadnes: This is the tool they are going to use 547 00:32:43,829 --> 00:32:46,830 For the installment of the window. 548 00:32:46,832 --> 00:32:48,932 Narrator: This ingenious suction mount, 549 00:32:48,934 --> 00:32:51,501 Specifically built for this installation, 550 00:32:51,503 --> 00:32:55,305 Uses 16 vacuum-powered suction cups to lift 551 00:32:55,307 --> 00:33:00,043 And precisely maneuver glass weighing up to 3 tons. 552 00:33:00,045 --> 00:33:03,780 This is perfect for installment on this type places, 553 00:33:03,782 --> 00:33:05,282 As we have on the bridge. 554 00:33:05,284 --> 00:33:08,385 Narrator: But even with this high-tech robotic arm, 555 00:33:08,387 --> 00:33:11,121 The team must take every precaution. 556 00:33:11,123 --> 00:33:14,424 Baadnes: The wind can take the glass as a sail, 557 00:33:14,426 --> 00:33:19,997 And it can turn around and damage the glass. 558 00:33:19,999 --> 00:33:22,032 Narrator: The team on the ground uses guy-lines 559 00:33:22,034 --> 00:33:24,434 Connected to the suction mount 560 00:33:24,436 --> 00:33:26,370 And keeps in constant communication 561 00:33:26,372 --> 00:33:29,272 With the crane operator, 562 00:33:29,274 --> 00:33:31,608 In a crucial effort to keep the glass steady 563 00:33:31,610 --> 00:33:34,811 If the winds increase. 564 00:33:34,813 --> 00:33:36,380 And the higher they go... 565 00:33:36,382 --> 00:33:38,248 [ indistinct chatter ] 566 00:33:38,250 --> 00:33:40,250 ...The windier it gets. 567 00:33:40,252 --> 00:33:44,921 ♪ 568 00:33:44,923 --> 00:33:47,758 The glass has just gone over the edge, 569 00:33:47,760 --> 00:33:52,562 So let's go up there and have a look at the final installment. 570 00:33:52,564 --> 00:33:56,400 Narrator: The team finally has the glass up to the bridge deck. 571 00:33:56,402 --> 00:33:58,869 But now they face the difficult task 572 00:33:58,871 --> 00:34:01,838 Of maneuvering it perfectly onto its frame. 573 00:34:01,840 --> 00:34:06,376 They have to tilt the tool to get it in the last stage. 574 00:34:06,378 --> 00:34:10,380 This is a very critical operation now. 575 00:34:10,382 --> 00:34:11,848 They're going to slide it in. 576 00:34:11,850 --> 00:34:15,552 It will take some tweaking to get it in place. 577 00:34:15,554 --> 00:34:17,287 Narrator: Every window on the ship 578 00:34:17,289 --> 00:34:20,590 Must be installed with millimeter precision. 579 00:34:20,592 --> 00:34:23,960 This is an expensive ship. Everything has to be perfect. 580 00:34:23,962 --> 00:34:25,729 Narrator: But even in the dock, 581 00:34:25,731 --> 00:34:28,131 Which is a controlled environment, 582 00:34:28,133 --> 00:34:32,235 The ship naturally rocks slightly from side to side. 583 00:34:32,237 --> 00:34:34,704 The crane's stationary location on land 584 00:34:34,706 --> 00:34:36,039 Makes positioning the glass 585 00:34:36,041 --> 00:34:40,177 On a moving target incredibly difficult. 586 00:34:40,179 --> 00:34:42,679 Because if the window touches the frame, 587 00:34:42,681 --> 00:34:47,017 It has a risk of actually shattering and breaking. 588 00:34:49,254 --> 00:34:51,755 Narrator: They use a laser to precisely examine 589 00:34:51,757 --> 00:34:56,293 All dimensions before inching the glass in towards the frame. 590 00:34:56,295 --> 00:35:01,765 It's a tense moment because they don't have a second chance. 591 00:35:01,767 --> 00:35:03,867 Narrator: It's a painstaking process, 592 00:35:03,869 --> 00:35:07,904 But finally, they slot the glass into position. 593 00:35:07,906 --> 00:35:09,272 Success! 594 00:35:09,274 --> 00:35:11,074 It fits perfectly. 595 00:35:11,076 --> 00:35:13,009 The big window is in the bridge. 596 00:35:13,011 --> 00:35:15,745 It's a big relief for everyone. 597 00:35:15,747 --> 00:35:18,215 Narrator: The team now has just four weeks to go 598 00:35:18,217 --> 00:35:19,883 To finish the ship. 599 00:35:19,885 --> 00:35:23,220 They work around the clock to install and seal 600 00:35:23,222 --> 00:35:25,489 The remaining bridge deck windows, 601 00:35:25,491 --> 00:35:28,225 Equip the cabins with electric wiring, 602 00:35:28,227 --> 00:35:31,061 Air-conditioning, and furnishings. 603 00:35:31,063 --> 00:35:34,798 ♪ 604 00:35:34,800 --> 00:35:38,301 To investigate if the team has fixed the crew cabin issues, 605 00:35:38,303 --> 00:35:42,939 Captain nils returns to the site with yard foreman sven. 606 00:35:42,941 --> 00:35:46,143 If captain nils isn't happy with the cabins this time, 607 00:35:46,145 --> 00:35:49,679 Fixing the issues could add weeks to the build. 608 00:35:49,681 --> 00:35:51,581 No damages. 609 00:35:51,583 --> 00:35:54,851 Nice and cold inside. 610 00:35:54,853 --> 00:35:59,122 And the sea fastening on this door will come later. 611 00:35:59,124 --> 00:36:03,093 This time, the captain seems pleased with the results. 612 00:36:03,095 --> 00:36:06,329 This is a big improvement since last time here. 613 00:36:06,331 --> 00:36:08,231 We were in the same cabin. 614 00:36:08,233 --> 00:36:10,400 So the quality is good. 615 00:36:10,402 --> 00:36:13,670 There is no damages, so... 616 00:36:13,672 --> 00:36:17,107 The crew will be very happy with these cabins. 617 00:36:17,109 --> 00:36:18,975 Narrator: The cabins may be done, 618 00:36:18,977 --> 00:36:22,779 But now the team faces a far bigger challenge. 619 00:36:22,781 --> 00:36:24,948 They must fire up the four 620 00:36:24,950 --> 00:36:28,351 3,600-horsepower diesel electric engines 621 00:36:28,353 --> 00:36:29,953 For the first time. 622 00:36:29,955 --> 00:36:33,356 If it goes really bad, the whole thing can just explode. 623 00:36:33,358 --> 00:36:36,293 ♪ 624 00:36:37,729 --> 00:36:41,831 ♪ 625 00:36:41,833 --> 00:36:44,167 Narrator: In the norwegian fjords, 626 00:36:44,169 --> 00:36:45,936 This army of engineers 627 00:36:45,938 --> 00:36:48,672 Has just two weeks to complete construction 628 00:36:48,674 --> 00:36:52,442 Of the world's biggest polar research vessel. 629 00:36:52,444 --> 00:36:55,378 Having battled through the harsh norwegian winter, 630 00:36:55,380 --> 00:36:58,281 They now face their biggest challenge. 631 00:36:58,283 --> 00:37:00,283 They must ensure that this vessel can run 632 00:37:00,285 --> 00:37:01,952 Under its own power. 633 00:37:01,954 --> 00:37:04,487 ♪ 634 00:37:04,489 --> 00:37:06,323 In the heart of the ship, 635 00:37:06,325 --> 00:37:11,328 The team prepares to ignite the engines for the first time. 636 00:37:11,330 --> 00:37:14,531 Chief engineer trond oversees the startup. 637 00:37:16,501 --> 00:37:18,101 Kjersem: So, today is a big day. 638 00:37:18,103 --> 00:37:21,938 It's really a milestone when you start the engines 639 00:37:21,940 --> 00:37:23,974 In a new build. 640 00:37:23,976 --> 00:37:28,211 We want to hear that the vessel is coming alive. 641 00:37:28,213 --> 00:37:32,549 Narrator: The pressure's on to make sure everything goes to plan. 642 00:37:32,551 --> 00:37:35,151 Without the engines, we wouldn't have anything. 643 00:37:35,153 --> 00:37:39,089 That creates the power that the vessel needs to operate, 644 00:37:39,091 --> 00:37:41,992 And to make sure that we meet delivery on time, 645 00:37:41,994 --> 00:37:44,094 This needs to happen today. 646 00:37:44,096 --> 00:37:46,496 Narrator: And this ship doesn't have just one engine, 647 00:37:46,498 --> 00:37:52,035 It has four 3,600-horsepower diesel electric powerhouses. 648 00:37:52,037 --> 00:37:55,905 Each costs a staggering $900,000 649 00:37:55,907 --> 00:38:00,243 And produces enough energy to supply 80 homes every day. 650 00:38:00,245 --> 00:38:02,379 Kjersem: On this vessel, we have two engine rooms 651 00:38:02,381 --> 00:38:03,980 With two engines in each. 652 00:38:03,982 --> 00:38:06,249 We can have accidents or fire 653 00:38:06,251 --> 00:38:08,618 And flooding occur in one of the engine rooms, 654 00:38:08,620 --> 00:38:10,787 And still we are able to sustain ourselves 655 00:38:10,789 --> 00:38:12,822 With the second engine room. 656 00:38:12,824 --> 00:38:16,526 Narrator: Trond and his team will start two engines today. 657 00:38:16,528 --> 00:38:20,263 It's a risky operation because the engines have been dormant 658 00:38:20,265 --> 00:38:23,099 Since they were last tested two years ago. 659 00:38:23,101 --> 00:38:25,535 Kjersem: If you have water inside the cylinder 660 00:38:25,537 --> 00:38:26,870 And you start cranking it, 661 00:38:26,872 --> 00:38:31,174 The valves and timing gear can explode. 662 00:38:31,176 --> 00:38:33,343 Narrator: Workers exit the engine room, 663 00:38:33,345 --> 00:38:36,079 To leave only essential crew. 664 00:38:36,081 --> 00:38:38,915 It's a bit nerve-wracking. 665 00:38:38,917 --> 00:38:40,784 -Man: All done? -Man #2: Yes. 666 00:38:40,786 --> 00:38:45,221 Narrator: It's time for the rev ocean to rev up. 667 00:38:45,223 --> 00:38:47,223 [ engine squealing ] 668 00:38:51,263 --> 00:38:53,296 [ engine shuts off ] 669 00:38:56,935 --> 00:39:01,071 After just a few seconds, the engine cuts out. 670 00:39:03,108 --> 00:39:04,507 As you could see, the first attempt 671 00:39:04,509 --> 00:39:07,577 Didn't work out all that well. 672 00:39:07,579 --> 00:39:11,181 Narrator: Engineers are under pressure to diagnose the problem, 673 00:39:11,183 --> 00:39:13,416 While up in the control room, 674 00:39:13,418 --> 00:39:17,253 Technicians analyze data to work out a solution. 675 00:39:17,255 --> 00:39:19,356 The clock is ticking. 676 00:39:19,358 --> 00:39:23,760 It would be not so good if we didn't get them running 677 00:39:23,762 --> 00:39:25,695 Because it will have a knock-on effect 678 00:39:25,697 --> 00:39:31,000 On the rest of the testing that we are waiting to follow now. 679 00:39:31,002 --> 00:39:33,436 Narrator: After a tense 10 minutes, 680 00:39:33,438 --> 00:39:36,172 The team figures out what caused the shutdown. 681 00:39:36,174 --> 00:39:38,475 Now we just got the message from the electronics guy 682 00:39:38,477 --> 00:39:40,243 In the engine control room. 683 00:39:40,245 --> 00:39:42,112 There seems to be a problem 684 00:39:42,114 --> 00:39:45,315 With one of the pickup sensors for the overspeed system. 685 00:39:45,317 --> 00:39:47,884 The overspeed sensors are in case the engine 686 00:39:47,886 --> 00:39:49,919 Is running faster and faster 687 00:39:49,921 --> 00:39:54,724 And going over the speed limit for this engine. 688 00:39:54,726 --> 00:39:57,660 If that happens, if it goes really bad, 689 00:39:57,662 --> 00:39:59,863 The whole thing can just explode. 690 00:39:59,865 --> 00:40:03,466 Narrator: They reset the sensors and clear the fuel lines 691 00:40:03,468 --> 00:40:06,603 Then press the starter button again. 692 00:40:06,605 --> 00:40:10,440 If it don't start now, well, I'm going home. 693 00:40:10,442 --> 00:40:11,808 [ chuckles ] 694 00:40:12,978 --> 00:40:15,044 [ engine squealing ] 695 00:40:15,046 --> 00:40:16,713 Narrator: Success! 696 00:40:16,715 --> 00:40:18,815 The engine springs to life. 697 00:40:21,653 --> 00:40:26,656 We've got the first one running, which is really amazing. 698 00:40:26,658 --> 00:40:29,859 Narrator: With engine number one getting a clear bill of health, 699 00:40:29,861 --> 00:40:31,995 They start engine number two. 700 00:40:33,565 --> 00:40:35,598 [ engine squealing ] 701 00:40:39,871 --> 00:40:42,305 Engine number two started on the first attempt. 702 00:40:42,307 --> 00:40:44,007 That's the way we like it. 703 00:40:44,009 --> 00:40:47,444 It's a huge milestone, not only for me, 704 00:40:47,446 --> 00:40:49,779 But also for the team, 705 00:40:49,781 --> 00:40:52,482 The project director, and the owner. 706 00:40:52,484 --> 00:40:56,453 Narrator: With the two engines in the main room up and running, 707 00:40:56,455 --> 00:41:00,023 Workers fire up the remaining engines 708 00:41:00,025 --> 00:41:03,760 And put the finishing touches on the internal spaces. 709 00:41:03,762 --> 00:41:06,796 Now this tough ice-busting vessel 710 00:41:06,798 --> 00:41:11,334 Is ready to tackle frozen arctic waters. 711 00:41:11,336 --> 00:41:13,770 Linningsvoll: This has been one of my biggest challenges, 712 00:41:13,772 --> 00:41:22,479 And I am very honored to be a part of this beautiful vessel. 713 00:41:22,481 --> 00:41:27,350 Baadnes: This is probably the best ship on the sea today, 714 00:41:27,352 --> 00:41:33,122 So I'm very lucky to be chosen to be captain on this vessel. 715 00:41:33,124 --> 00:41:37,527 Narrator: With the first polar expedition scheduled for 2021, 716 00:41:37,529 --> 00:41:39,863 This ice-slicing megaship 717 00:41:39,865 --> 00:41:43,766 Will now sail some of the most dangerous seas on earth, 718 00:41:43,768 --> 00:41:48,438 On a mission to uncover the secrets of our oceans. 719 00:41:48,440 --> 00:41:51,574 Having dedicated my life to fixing the ocean, 720 00:41:51,576 --> 00:41:54,577 I now finally think that we have a fighting chance. 721 00:41:54,579 --> 00:42:04,554 ♪ 63673

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