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Narrator: A DRAGSTER'S TIRES
TAKE QUITE A BEATING
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00:00:55,758 --> 00:00:59,137
DURING THE BRIEF,
BUT FAST RUN DOWN THE RACETRACK.
3
00:00:59,137 --> 00:01:01,827
THE TIRES HAVE TO FACE
FULL-ON ACCELERATION
4
00:01:01,827 --> 00:01:03,724
RIGHT OUT OF THE STARTING GATE,
5
00:01:03,724 --> 00:01:06,413
THEN HEAVY-DUTY BRAKING
AFTER THE FINISH LINE,
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00:01:06,413 --> 00:01:08,586
WITH THE CAR
DEPLOYING A REAR PARACHUTE
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00:01:08,586 --> 00:01:11,448
AND SLOWING TO AN EVENTUAL STOP.
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00:01:13,655 --> 00:01:17,310
A DRAG RACE IS
THE ULTIMATE AUTOMOTIVE SPRINT,
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00:01:17,310 --> 00:01:18,620
WITH RAPID ACCELERATION
10
00:01:18,620 --> 00:01:22,137
TO SPEEDS
TOPPING 310 MILES PER HOUR.
11
00:01:22,137 --> 00:01:25,827
OPTIMAL TIRE TRACTION
CAN GIVE A CAR THE WINNING EDGE.
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00:01:25,827 --> 00:01:29,862
DRAGSTER TIRES, LIKE MOST TIRES,
ARE MADE FROM RUBBER,
13
00:01:29,862 --> 00:01:33,068
WHICH HASN'T BEEN CURED
TO A FIRM AND PERMANENT STATE.
14
00:01:33,068 --> 00:01:34,758
FOR MOST PARTS OF THE TIRE,
15
00:01:34,758 --> 00:01:38,172
THEY REINFORCE THE RUBBER
WITH NYLON FABRIC.
16
00:01:38,172 --> 00:01:41,103
THE MACHINE HEATS AND KNEADS
RUBBER SLABS UNTIL THEY MELT,
17
00:01:41,103 --> 00:01:44,965
THEN COATS BOTH SIDES OF THE
MATERIAL WITH A MOLTEN RUBBER.
18
00:01:44,965 --> 00:01:48,000
WHEN THE FABRIC-REINFORCED
SHEET OF RUBBER COOLS,
19
00:01:48,000 --> 00:01:51,655
THE MACHINE SLICES IT INTO
PIECES OF A SPECIFIC LENGTH,
20
00:01:51,655 --> 00:01:55,413
MAKING THE CUTS AT A DIAGONAL,
CALLED A BIAS ANGLE.
21
00:01:55,413 --> 00:01:58,689
A SKILLED TIRE BUILDER THEN
JOINS THE EDGES OF THE PIECE
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00:01:58,689 --> 00:01:59,724
TO FORM A BAND,
23
00:01:59,724 --> 00:02:01,862
STICKS IT TO AN IDENTICAL BAND
24
00:02:01,862 --> 00:02:04,344
MADE OF
AN OPPOSITE BIAS PIECE --
25
00:02:04,344 --> 00:02:06,448
LAYERING INCREASES STRENGTH --
26
00:02:06,448 --> 00:02:11,137
THEN STRETCHES THIS TWO-PLY BAND
OVER A TIRE-BUILDING MACHINE.
27
00:02:11,137 --> 00:02:12,862
NEXT, HE APPLIES THE BELTS,
28
00:02:12,862 --> 00:02:16,206
TWO OPPOSING BIAS PIECES
OF FABRIC-REINFORCED RUBBER,
29
00:02:16,206 --> 00:02:20,793
WHICH HE LAYS DIAGONALLY ONTO
THE TREAD AREA OF THE TIRE.
30
00:02:20,793 --> 00:02:23,586
A LASER GUIDE MARKS THE EDGES
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00:02:23,586 --> 00:02:26,448
SO THAT HE CAN MATCH THE BELTS
TO EACH OTHER.
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00:02:26,448 --> 00:02:29,827
THESE BELTS HELP GIVE THE TIRE
STIFFNESS, STRENGTH,
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00:02:29,827 --> 00:02:31,551
AND STABILITY.
34
00:02:36,034 --> 00:02:38,931
HE USES A ROLLER
TO PRESS OUT ANY TRAPPED AIR
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00:02:38,931 --> 00:02:41,000
BETWEEN THE PLIES AND BELTS.
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00:02:41,000 --> 00:02:43,689
THIS HELPS ENSURE
A THOROUGH BOND.
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00:02:43,689 --> 00:02:47,241
AFTER A STITCHER WHEEL
FOLDS DOWN THE PLIES,
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00:02:47,241 --> 00:02:50,793
HE FOLDS THE ENDS OF
THE MATERIAL INTO THE MACHINE.
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00:02:50,793 --> 00:02:53,827
THEN, HE APPLIES
A CONTACT CEMENT-TYPE MATERIAL
40
00:02:53,827 --> 00:02:57,310
TO ENHANCE THE NATURAL ADHESION
OF UNCURED RUBBER.
41
00:02:57,310 --> 00:03:02,275
MEANWHILE, AN AUTOMATED MACHINE
MAKES THE TIRES' BEADS,
42
00:03:02,275 --> 00:03:05,034
THE RIGID HOOPS AROUND BOTH
SIDES OF THE OPENING,
43
00:03:05,034 --> 00:03:07,344
WHICH HOLDS THE TIRE
FIRMLY TO THE WHEEL.
44
00:03:07,344 --> 00:03:10,862
EACH BEAD IS MADE
FROM A THICK, STEEL WIRE.
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00:03:10,862 --> 00:03:15,206
THE MACHINE
FIRST ENCAPSULATES IT IN RUBBER.
46
00:03:23,413 --> 00:03:27,551
THEN, IT WINDS THE BEAD AROUND
A MANDRILL UP TO 50 TIMES,
47
00:03:27,551 --> 00:03:28,689
FORMING A HOOP.
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00:03:28,689 --> 00:03:31,931
THE MACHINE FORMS FOUR BEADS
AT A TIME.
49
00:03:37,034 --> 00:03:38,931
THE NEXT MACHINE WRAPS THE HOOP
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00:03:38,931 --> 00:03:41,413
IN A PIECE
OF FABRIC-REINFORCED RUBBER.
51
00:03:41,413 --> 00:03:44,655
THIS ADDITIONAL LAYER
WILL STIFFEN THE SIDEWALL,
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00:03:44,655 --> 00:03:46,965
THE NON-TREADED AREA
OF THE TIRE.
53
00:03:51,931 --> 00:03:54,689
THE BUILDER USES A TOOL
CALLED A BEAD SERVER
54
00:03:54,689 --> 00:03:57,068
TO MOUNT THE FINISHED BEAD.
55
00:03:57,068 --> 00:03:58,793
WHILE THE TIRE IS SPINNING,
56
00:03:58,793 --> 00:04:01,620
HE APPLIES THE CONTACT
CEMENT-TYPE MATERIAL
57
00:04:01,620 --> 00:04:03,896
TO HELP
THE RUBBER-TO-RUBBER ADHESION
58
00:04:03,896 --> 00:04:07,482
WHEN HE WRAPS THE PLIES AROUND
THE BEAD TO SECURE IT FURTHER.
59
00:04:11,413 --> 00:04:14,793
THE STITCHER WHEEL
SMOOTHES THE PLIES FLAT
60
00:04:14,793 --> 00:04:17,965
AND PUSHES OUT TRAPPED AIR.
61
00:04:17,965 --> 00:04:19,482
THEN, THE TIRE BUILDER
62
00:04:19,482 --> 00:04:23,758
APPLIES A STRIP OF
FABRIC-REINFORCED RUBBER ON TOP
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00:04:23,758 --> 00:04:25,068
AND ROLLS IT FLAT.
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00:04:25,068 --> 00:04:28,103
THIS STRIP WILL MAKE
THE BEAD AREA MORE DURABLE
65
00:04:28,103 --> 00:04:30,758
WHEN THE TIRE
IS MOUNTED ON A WHEEL.
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00:04:30,758 --> 00:04:33,034
HE APPLIES A LAYER
OF NON-REINFORCED RUBBER
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00:04:33,034 --> 00:04:34,068
ON THE SIDEWALL.
68
00:04:34,068 --> 00:04:36,931
THIS COVERS
THE EDGES OF THE PLIES
69
00:04:36,931 --> 00:04:40,758
AND WILL HELP THE TIRE
RETAIN AIR ONCE IT'S INFLATED.
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00:04:40,758 --> 00:04:44,172
THIS MACHINE MAKES THE TREAD BY
EXTRUDING MOLTEN RUBBER
71
00:04:44,172 --> 00:04:47,000
THROUGH A DYE
INTO A CONTINUOUS STRIP,
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00:04:47,000 --> 00:04:50,413
THEN APPLYING IT
ONTO THE SPINNING TIRE.
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00:04:50,413 --> 00:04:54,241
THE FULLY CONSTRUCTED TIRE
NOW GOES INTO A PRESS TO CURE.
74
00:04:54,241 --> 00:04:57,689
INSIDE, A HOT MOLD CLOSES
AROUND THE PERIMETER,
75
00:04:57,689 --> 00:04:59,724
WHILE A BAG INFLATES
IN THE MIDDLE,
76
00:04:59,724 --> 00:05:03,137
PUSHING THE TIRE OUTWARD
AGAINST THE WALLS OF THE MOLD.
77
00:05:03,137 --> 00:05:05,724
WHEN THE TIRE COMES OUT,
ABOUT HALF AN HOUR LATER,
78
00:05:05,724 --> 00:05:08,172
THE RUBBER IS NO LONGER
SOFT AND PLIABLE,
79
00:05:08,172 --> 00:05:10,931
AND ITS CHEMICAL STRUCTURE
IS STABILIZED,
80
00:05:10,931 --> 00:05:13,413
LOCKING IN THE FINAL DIMENSIONS.
81
00:05:13,413 --> 00:05:16,413
WORKERS SEAL THE WHEEL OPENING
AND INFLATE THE TIRE
82
00:05:16,413 --> 00:05:19,793
TO HOLD THE SHAPE
UNTIL THE RUBBER COOLS.
83
00:05:19,793 --> 00:05:21,827
ONCE THE RUBBER HAS COOLED
TO ROOM TEMPERATURE,
84
00:05:21,827 --> 00:05:23,344
WHICH TAKES ABOUT AN HOUR,
85
00:05:23,344 --> 00:05:26,620
THE TIRE UNDERGOES A SERIES
OF QUALITY-CONTROL CHECKS.
86
00:05:26,620 --> 00:05:29,931
HERE, A WORKER PERFORMS
A VISUAL INSPECTION
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00:05:29,931 --> 00:05:33,379
WHILE TRIMMING OFF EXCESS RUBBER
FROM THE BEAD AREA.
88
00:05:33,379 --> 00:05:37,448
BEFORE THE DECALS GO ON,
THEY ALSO X-RAY THE TIRE,
89
00:05:37,448 --> 00:05:40,793
LOOKING FOR ANY INTERNAL FLAWS.
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00:05:40,793 --> 00:05:44,172
LIFE IN THE FAST LANE,
WHILE EXCITING, IS SHORT.
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00:05:44,172 --> 00:05:46,172
DRAGSTER TIRES
NEED TO BE REPLACED
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00:05:46,172 --> 00:05:50,000
EVERY FOUR TO SIX TRIPS
DOWN THE DRAG STRIP.
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00:06:02,551 --> 00:06:04,724
Narrator: ICING DATES BACK
TO 17th-CENTURY ENGLAND.
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00:06:04,724 --> 00:06:07,586
EARLY VERSIONS
WERE POURED DIRECTLY ONTO CAKE.
95
00:06:07,586 --> 00:06:09,517
THE CAKE WAS THEN
PUT BACK IN THE OVEN
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00:06:09,517 --> 00:06:12,206
UNTIL THE TOPPING
COOKED INTO AN ICELIKE GLAZE,
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00:06:12,206 --> 00:06:14,310
HENCE THE TERM ICING.
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00:06:14,310 --> 00:06:18,862
HUNDREDS OF YEARS LATER,
SUCCESS NEVER TASTED SWEETER.
99
00:06:22,965 --> 00:06:26,586
TODAY, ICING COMES READY-MADE
IN CANS AND TUBES.
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00:06:26,586 --> 00:06:29,758
NO NEED TO MAKE A STICKY MESS
IN THE KITCHEN.
101
00:06:29,758 --> 00:06:32,758
JUST PRESS THE NOZZLE
TO TRANSFORM A PLAIN CUPCAKE
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00:06:32,758 --> 00:06:36,137
INTO AN ELABORATE DESSERT.
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00:06:36,137 --> 00:06:40,034
IT TAKES A DOZEN DIFFERENT
INGREDIENTS TO MAKE ICING,
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00:06:40,034 --> 00:06:43,206
BEGINNING WITH
VEGETABLE-OIL SHORTENING.
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00:06:43,206 --> 00:06:46,758
THEY ENCAPSULATE FOOD COLORING
IN THE BLOCK OF SHORTENING.
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00:06:46,758 --> 00:06:49,620
THIS KEEPS THE FOOD COLORING
FROM BECOMING AIRBORNE,
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00:06:49,620 --> 00:06:52,206
AS A MIXTURE CREAMS
THE SHORTENING WITH SUGAR,
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00:06:52,206 --> 00:06:55,275
WHICH THEY PIPE
DIRECTLY INTO THE MIXER BASIN.
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00:06:55,275 --> 00:06:58,103
SUGAR IS THE MAIN INGREDIENT
IN ICING.
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00:07:02,172 --> 00:07:04,655
CORN SYRUP
IS THE NEXT INGREDIENT.
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00:07:04,655 --> 00:07:09,172
IT ADDS MORE SWEETNESS
AND LIQUIDITY TO THE MIX.
112
00:07:09,172 --> 00:07:12,413
THE MIXER ARM SPIRALS AROUND
THE BASIN FOR A FEW MINUTES
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00:07:12,413 --> 00:07:16,724
TO BLEND EVERYTHING.
114
00:07:16,724 --> 00:07:21,931
THEN, THEY ADD CORNSTARCH, WHICH
WILL ACT AS A THICKENING AGENT.
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00:07:21,931 --> 00:07:25,965
THEY POUR WARM WATER INTO THE
MIXTURE AND BEAT UNTIL SMOOTH.
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00:07:25,965 --> 00:07:28,724
IF THE ICING CONSISTENCY
IS TOO THIN,
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00:07:28,724 --> 00:07:32,103
THEY THICKEN IT WITH MORE SUGAR.
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00:07:32,103 --> 00:07:35,448
THIS 1,000-POUND BATCH OF ICING
IS DONE,
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00:07:35,448 --> 00:07:40,068
AND THERE'S ENOUGH TO FILL
2,000 ALUMINUM CANS.
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00:07:40,068 --> 00:07:42,896
A CONVEYOR
DELIVERS THE CANS TO FILLERS
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00:07:42,896 --> 00:07:46,517
THAT INJECT HALF A POUND
OF ICING INTO EACH CAN.
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00:07:52,689 --> 00:07:55,689
THE SYSTEM FILLS
3,600 CANS AN HOUR,
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00:07:55,689 --> 00:07:59,137
AND NO ONE HAS TO GET
THEIR FINGERS STICKY.
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00:07:59,137 --> 00:08:02,275
PLASTIC NOZZLES NOW FUNNEL
TOWARD THE CONTAINERS,
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00:08:02,275 --> 00:08:03,862
AND WITH PERFECT TIMING,
126
00:08:03,862 --> 00:08:08,310
A PRESS SEALS ONE TO EACH
OF THE ICING-FILLED CANS.
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00:08:10,310 --> 00:08:11,793
AT THE SAME TIME,
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00:08:11,793 --> 00:08:15,448
A PUMP SHOOTS AIR INTO A SMALL
HOLE IN THE BOTTOM OF THE CAN.
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00:08:15,448 --> 00:08:19,482
THIS PRESSURIZES THE ICING SO IT
CAN BE PUMPED OUT WHEN NEEDED.
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00:08:21,206 --> 00:08:23,965
THE BURST OF AIR CARRIES
A TINY, RUBBER CAP WITH IT,
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00:08:23,965 --> 00:08:27,482
AND IT PLUGS THE HOLE
TO MAINTAIN THE PRESSURE.
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00:08:29,724 --> 00:08:34,068
THE CANS MOVE FORWARD AND MEET
UP WITH THE APPLICATOR TIPS.
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00:08:36,517 --> 00:08:39,137
THERE ARE FOUR TIPS PER CAN,
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00:08:39,137 --> 00:08:42,172
HELD TOGETHER
BY LITTLE, PLASTIC CONNECTORS.
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00:08:42,172 --> 00:08:45,310
THE FOUR APPLICATOR CLUSTERS
FALL OUT OF THE FEEDER
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00:08:45,310 --> 00:08:47,344
AND LAND ON THE CAN NOZZLES.
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00:08:48,931 --> 00:08:52,586
CLEAR CAPS THEN FALL INTO PLACE
ON THE CANS.
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00:08:56,517 --> 00:08:59,896
A BLADE CUTS A LABELED PLASTIC
SLEEVE TO THE CORRECT LENGTH.
139
00:08:59,896 --> 00:09:02,551
THE SLEEVE DROPS ONTO THE CANS,
140
00:09:02,551 --> 00:09:05,000
DRAPING THEM LOOSELY
FOR THE MOMENT.
141
00:09:08,137 --> 00:09:10,620
THEY RIDE BY
A SPINNING PLASTIC DISK
142
00:09:10,620 --> 00:09:13,068
THAT TUCKS THE SLEEVES
ALL THE WAY DOWN.
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00:09:15,689 --> 00:09:17,379
THEN, IT'S INTO A DRIER,
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00:09:17,379 --> 00:09:21,551
WHERE THE HEAT SHRINKS THE WRAP
TO THE CANS, SEALING THE ICING.
145
00:09:23,862 --> 00:09:26,379
IT'S A PERFECT FIT.
146
00:09:31,172 --> 00:09:35,758
NEXT, THEY MAKE ICING
FOR PACKAGING IN SQUEEZE TUBES.
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00:09:35,758 --> 00:09:38,172
THEY BLEND TOGETHER
THE SAME INGREDIENTS,
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00:09:38,172 --> 00:09:41,517
BUT IN DIFFERENT AMOUNTS
AND IN A DIFFERENT ORDER.
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00:09:41,517 --> 00:09:44,586
THIS ACHIEVES
A THICKER CONSISTENCY.
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00:09:44,586 --> 00:09:48,517
THICKER ICING CAN BE MORE
EASILY SQUEEZED OUT OF TUBES.
151
00:09:50,068 --> 00:09:55,034
FOR READY-MADE ICING, IT REALLY
IS ALL IN THE PACKAGING.
152
00:09:55,034 --> 00:09:57,724
A MECHANIZED ARM
PICKS UP THE SQUEEZE TUBE
153
00:09:57,724 --> 00:10:00,655
AND DELIVERS IT
TO THE FILLING MACHINE.
154
00:10:03,413 --> 00:10:07,413
A VACUUM PUMP SUCKS OUT AIR
AND ANY CONTAMINANTS.
155
00:10:09,137 --> 00:10:13,517
ANOTHER MECHANISM
ORIENTS THE TUBE FOR FILLING.
156
00:10:13,517 --> 00:10:16,413
NOZZLES NOW INJECT THICK,
YELLOW ICING INTO THE TUBES,
157
00:10:16,413 --> 00:10:18,275
BUT STOP SHORT
AT A COMPLETE FILL-UP,
158
00:10:18,275 --> 00:10:21,448
LEAVING SPACE
FOR THE OPEN ENDS TO BE CLOSED
159
00:10:21,448 --> 00:10:23,379
AND SEALED BY HOT JAWS.
160
00:10:29,172 --> 00:10:33,034
ONCE CLOSED,
THE MACHINE EJECTS THE TUBES.
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00:10:33,034 --> 00:10:36,551
EACH ONE CONTAINS
FOUR OUNCES OF ICING.
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00:10:36,551 --> 00:10:39,068
IT'S ABOUT HALF AS MUCH
AS THE CAN.
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00:10:39,068 --> 00:10:41,965
TO DECORATE WITH ICING
FROM A TUBE,
164
00:10:41,965 --> 00:10:45,965
THE CONSUMER SQUEEZES IT
OUT OF THE BOTTOM TIP.
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00:10:45,965 --> 00:10:51,344
TO APPLY ICING FROM A CAN,
YOU PUMP IT OUT OF THE TOP.
166
00:10:51,344 --> 00:10:55,931
NO MATTER HOW YOU ICE IT,
THE RESULT WILL BE SWEET.
167
00:11:09,827 --> 00:11:12,482
THE EGYPTIANS
BUILT THE EARLIEST KNOWN DOCKS
168
00:11:12,482 --> 00:11:15,137
ON THE SHORES OF THE RED SEA
AROUND 2500 BC.
169
00:11:15,137 --> 00:11:17,379
MORE THAN 4,000 YEARS LATER,
170
00:11:17,379 --> 00:11:20,620
OUR LAKES AND RIVERS ARE DOTTED
WITH FLOATING STRUCTURES
171
00:11:20,620 --> 00:11:23,931
WHERE BOATERS CAN DOCK
THEIR CRAFTS, GO FOR A DIP,
172
00:11:23,931 --> 00:11:28,793
OR JUST LOUNGE IN THE SUN.
173
00:11:28,793 --> 00:11:30,689
FLOATING DOCKS CAN BE MUCH MORE
174
00:11:30,689 --> 00:11:33,482
THAN JUST WALKWAYS
WHERE YOU TIE UP YOUR BOAT.
175
00:11:33,482 --> 00:11:37,413
THEY CAN BE WATERBORNE BUILDINGS
WITH SLIPS, JET-SKI PORTS,
176
00:11:37,413 --> 00:11:40,793
AND EVEN A ROOFTOP DECK.
177
00:11:40,793 --> 00:11:42,413
THIS FACILITY HAS CREATED
178
00:11:42,413 --> 00:11:45,310
ITS OWN COMPUTER-AIDED
DESIGN SOFTWARE.
179
00:11:45,310 --> 00:11:49,551
WITH IT, THEY CAN QUICKLY DESIGN
EACH COMPONENT OF A DOCK IN 3-D.
180
00:11:49,551 --> 00:11:52,896
THE PROGRAM WILL EVEN CALCULATE
HOW MANY FLOATS ARE NEEDED
181
00:11:52,896 --> 00:11:54,379
AND WHERE THEY SHOULD BE PLACED
182
00:11:54,379 --> 00:11:57,206
TO KEEP THE DOCK LEVEL
IN THE WATER.
183
00:11:57,206 --> 00:12:00,448
THANKS TO ITS LIGHTWEIGHT,
RUSTPROOF STRENGTH,
184
00:12:00,448 --> 00:12:04,103
ALUMINUM IS THE IDEAL MATERIAL
FOR BUILDING DOCKS.
185
00:12:04,103 --> 00:12:07,724
ALL THE ALUMINUM HERE HAS BEEN
EXTRUDED IN UNIQUE SHAPES
186
00:12:07,724 --> 00:12:10,517
ACCORDING
TO THE DESIGN REQUIREMENTS.
187
00:12:10,517 --> 00:12:13,793
THE PLANS ARE PRINTED,
AND WORKERS CONSULT THEM CLOSELY
188
00:12:13,793 --> 00:12:16,310
AS THEY CUT
AND FORM THE MATERIAL.
189
00:12:16,310 --> 00:12:18,655
THE BLADES THEY USE
ARE SPECIALLY DESIGNED
190
00:12:18,655 --> 00:12:20,206
FOR CUTTING ALUMINUM.
191
00:12:20,206 --> 00:12:23,275
THEY USE A VARIETY OF METHODS
TO FORM THE SHAPES,
192
00:12:23,275 --> 00:12:26,137
INCLUDING DRILL PRESSES
EQUIPPED WITH COMPONENTS
193
00:12:26,137 --> 00:12:28,068
CALLED HOLE SAWS.
194
00:12:29,482 --> 00:12:32,206
WORKERS LAY THE MATERIAL OUT
ON THE FACTORY FLOOR
195
00:12:32,206 --> 00:12:35,448
IN PREPARATION
FOR ASSEMBLING THE STRUCTURE.
196
00:12:35,448 --> 00:12:37,689
THE FINAL ASSEMBLY
OF THE FLOATING DOCKS
197
00:12:37,689 --> 00:12:42,517
WILL HAPPEN ON THE WATER
AT THE SITE.
198
00:12:42,517 --> 00:12:45,034
THEY TACK-WELD THE PARTS
TO EACH OTHER,
199
00:12:45,034 --> 00:12:47,586
THEN MAKE SURE
EVERYTHING IS PERFECTLY SQUARE
200
00:12:47,586 --> 00:12:50,275
BEFORE DOING THE FINAL WELD.
201
00:12:50,275 --> 00:12:54,724
UNLIKE STEEL, ALUMINUM LOSES
STRENGTH WHEN IT'S WELDED.
202
00:12:54,724 --> 00:12:57,379
FOR THIS REASON,
THE DESIGNERS OF THESE DOCKS
203
00:12:57,379 --> 00:13:01,827
HAVE CREATED SPECIAL ALUMINUM
SLEEVES FOR EVERY MAJOR JOINT.
204
00:13:01,827 --> 00:13:04,103
THAT MEANS THERE'S EXTRA METAL
SUPPORTING THE WELD
205
00:13:04,103 --> 00:13:08,068
AND STRENGTHENING THE STRUCTURE.
206
00:13:08,068 --> 00:13:10,275
TO MAKE SURE
EVERYTHING FITS PROPERLY,
207
00:13:10,275 --> 00:13:13,517
THE WORKERS JOIN THE SECTIONS
TO EACH OTHER
208
00:13:13,517 --> 00:13:16,620
WITH STAINLESS-STEEL BOLTS
AND LOCK NUTS.
209
00:13:16,620 --> 00:13:19,379
THERE IS MINIMAL REACTION
BETWEEN THE DIFFERENT METALS,
210
00:13:19,379 --> 00:13:21,517
BECAUSE THERE IS
SO LITTLE STAINLESS STEEL
211
00:13:21,517 --> 00:13:25,068
RELATIVE TO THE QUANTITY
OF ALUMINUM BEING USED.
212
00:13:25,068 --> 00:13:28,137
ONCE THE BOTTOM SECTION
OF THE DOCK IS ASSEMBLED,
213
00:13:28,137 --> 00:13:30,379
WORKERS BUILD UP FROM THERE.
214
00:13:30,379 --> 00:13:32,517
FOR THIS TEST PHASE,
THEY USE SHORTENED,
215
00:13:32,517 --> 00:13:36,275
TEMPORARY ROOF POLES
TO MAKE THE PROCESS EASIER.
216
00:13:36,275 --> 00:13:39,413
THE BLUE MATERIAL ON THE POLES
IS POLYETHYLENE BUSHING,
217
00:13:39,413 --> 00:13:41,448
WHICH PREVENTS CREAKING
218
00:13:41,448 --> 00:13:44,689
WHEN THE DOCK IS STRESSED
IN TURBULENT WATER.
219
00:13:44,689 --> 00:13:46,896
BECAUSE ALUMINUM
IS SO LIGHTWEIGHT,
220
00:13:46,896 --> 00:13:50,034
THERE'S NO NEED FOR CRANES
IN AN ALUMINUM DOCK FACILITY.
221
00:13:50,034 --> 00:13:54,482
MANPOWER IS ENOUGH.
222
00:13:54,482 --> 00:13:57,862
WORKERS ATTACH A SERIES
OF NARROW, ALUMINUM TUBES,
223
00:13:57,862 --> 00:14:00,413
CALLED PURLINS,
TO THE ROOF AND DECK.
224
00:14:00,413 --> 00:14:04,344
WORKERS INSTALL THE ROOFING
BY SCREWING IT INTO THE PURLINS.
225
00:14:04,344 --> 00:14:06,965
IN MOST CASES,
THE ROOF WON'T BE INSTALLED
226
00:14:06,965 --> 00:14:10,241
UNTIL THE DOCK IS ASSEMBLED
ON-SITE.
227
00:14:10,241 --> 00:14:12,931
SATISFIED THAT EVERYTHING
ASSEMBLES CORRECTLY,
228
00:14:12,931 --> 00:14:15,310
THE WORKERS TAKE IT ALL APART.
229
00:14:15,310 --> 00:14:19,206
THEY FLIP THE LOWER SECTIONS
OVER AND ATTACH THE FLOATS.
230
00:14:19,206 --> 00:14:22,655
THESE FLOATS CONSIST OF
ROTO-MOLDED POLYETHYLENE SHELLS.
231
00:14:22,655 --> 00:14:26,137
STYROFOAM HAS BEEN
EXPANDED IN PLACE
232
00:14:26,137 --> 00:14:28,034
TO FIT INSIDE THE SHELL
PERFECTLY.
233
00:14:28,034 --> 00:14:32,137
EVEN IF THE OUTER SHELL BREAKS,
THE DOCK WILL STILL FLOAT.
234
00:14:33,689 --> 00:14:36,758
THIS FACILITY OFFERS
A RANGE OF DECKING OPTIONS
235
00:14:36,758 --> 00:14:40,137
FROM ALUMINUM TO CONCRETE
TO PLASTIC COMPOSITE
236
00:14:40,137 --> 00:14:43,758
TO SPECIALTY WOODS LIKE
THIS ONE, WHICH IS CALLED IPE.
237
00:14:43,758 --> 00:14:48,413
LIKE TEAK, IPE IS INCREDIBLY
DURABLE AND EXTREMELY STABLE.
238
00:14:48,413 --> 00:14:51,793
IN OTHER WORDS, IT WON'T ROT,
SWELL, OR CONTRACT,
239
00:14:51,793 --> 00:14:56,137
DESPITE EXTENDED EXPOSURE
TO A HIGH-HUMIDITY ENVIRONMENT.
240
00:14:59,344 --> 00:15:03,448
IF THE DOCK HAS AN UPPER DECK,
IT NEEDS A RAILING.
241
00:15:03,448 --> 00:15:05,241
IT'S IMPORTANT TO HAVE SOMETHING
TO LEAN AGAINST
242
00:15:05,241 --> 00:15:07,724
WHEN YOU'RE SIPPING COCKTAILS
AND WATCHING THE SUNSET
243
00:15:07,724 --> 00:15:08,931
AFTER A LONG BOAT RIDE.
244
00:15:08,931 --> 00:15:12,758
OF COURSE, IT'S ALSO
A CRUCIAL SAFETY FEATURE.
245
00:15:12,758 --> 00:15:15,827
THERE ARE 12 DIFFERENT
COMPONENTS TO ASSEMBLE
246
00:15:15,827 --> 00:15:17,551
FOR JUST THIS ONE SECTION,
247
00:15:17,551 --> 00:15:20,793
AND THERE MIGHT BE AS MANY
AS 15 DIFFERENT SECTIONS
248
00:15:20,793 --> 00:15:23,448
OF VARYING LENGTHS
FOR AN ENTIRE DOCK.
249
00:15:25,275 --> 00:15:28,103
CUSTOMERS CAN CHOOSE TO ADD
A RANGE OF ACCESSORIES
250
00:15:28,103 --> 00:15:30,620
TO FLOATING DOCKS
MADE AT THIS FACILITY.
251
00:15:30,620 --> 00:15:33,000
TO MAKE THINGS LIKE SAFETY
RAILINGS AND LADDERS,
252
00:15:33,000 --> 00:15:36,172
WORKERS USE
A HYDRAULIC BENDING MACHINE
253
00:15:36,172 --> 00:15:39,517
TO SHAPE ALUMINUM TUBING
TO THE REQUIRED CONTOURS.
254
00:15:39,517 --> 00:15:41,758
ALL THE ALUMINUM THESE
MANUFACTURERS USE
255
00:15:41,758 --> 00:15:44,689
IN THEIR FLOATING DOCKS
IS A MARINE-GRADE ALLOY
256
00:15:44,689 --> 00:15:47,137
ESPECIALLY RESISTANT
TO DEGRADATION
257
00:15:47,137 --> 00:15:49,758
WHEN EXPOSED TO WATER.
258
00:15:49,758 --> 00:15:52,724
FINALLY, IT'S TIME TO BUILD
THE DOCKS IN PLACE.
259
00:15:52,724 --> 00:15:56,241
THANKS TO CAREFUL PLANNING ON
THE PART OF THE MANUFACTURERS,
260
00:15:56,241 --> 00:15:58,000
ASSEMBLY IS A BREEZE.
261
00:15:58,000 --> 00:16:00,551
THE CREW DOESN'T NEED
MUCH MORE THAN A RATCHET SET
262
00:16:00,551 --> 00:16:02,241
TO PULL IT ALL TOGETHER.
263
00:16:02,241 --> 00:16:05,517
IT'S SMOOTH SAILING
FROM HERE ON OUT.
264
00:16:17,379 --> 00:16:19,793
IN THE MODERN WORLD, STEEL PIPES
FORM AN UNDERGROUND NETWORK
265
00:16:19,793 --> 00:16:23,172
TO DELIVER NECESSITIES
LIKE DRINKING WATER OR FUEL.
266
00:16:23,172 --> 00:16:25,793
THESE PIPES ARE OFTEN
SPIRALLY WELDED
267
00:16:25,793 --> 00:16:28,103
AND CAN BE MADE IN ANY SIZE.
268
00:16:28,103 --> 00:16:31,172
IN FACT, LONGER PIPE
MEANS FEWER JOINTS
269
00:16:31,172 --> 00:16:34,379
AND LESS WORK
TO INSTALL THEM UNDERGROUND.
270
00:16:37,896 --> 00:16:42,551
SPIRALLY WELDED PIPES CAN BE
SHORT, OR THEY CAN GO ON AND ON.
271
00:16:42,551 --> 00:16:44,586
THE POTENTIAL LENGTH
IS LIMITLESS,
272
00:16:44,586 --> 00:16:46,758
BECAUSE,
UNLIKE OTHER KINDS OF PIPES,
273
00:16:46,758 --> 00:16:48,965
SPIRAL PIPES
DON'T HAVE TO CONFORM
274
00:16:48,965 --> 00:16:53,586
TO THE SIZE OF A FORMING ROLL OR
THE DIMENSIONS OF A STEEL PLATE.
275
00:16:53,586 --> 00:16:58,275
THEY CAN SPIRAL-WELD THESE COILS
OF STEEL SHEETS ENDLESSLY.
276
00:17:01,103 --> 00:17:04,931
BUT FIRST THEY HAVE TO TAKE THE
KINK OUT OF THE COILED STEEL.
277
00:17:04,931 --> 00:17:08,068
A MACHINE UNWINDS IT
278
00:17:08,068 --> 00:17:13,448
AND PUSHES IT BETWEEN ROLLERS
TO COMPLETELY FLATTEN IT.
279
00:17:13,448 --> 00:17:15,758
A FIXED ARM THEN PRESSES
THE STEEL AGAINST ROLLERS
280
00:17:15,758 --> 00:17:19,413
TO ROUND IT
TO A PRECISE DIAMETER,
281
00:17:19,413 --> 00:17:23,482
AND AN AUTOMATED SYSTEM WELDS
THE FORMED PIPE FROM THE INSIDE.
282
00:17:23,482 --> 00:17:26,068
A BARELY VISIBLE MANTEL
OF POWDERED FLUX
283
00:17:26,068 --> 00:17:28,448
PROTECTS THE WELDING PROCESS.
284
00:17:31,896 --> 00:17:34,034
COPPER-COATED STEEL WIRE
285
00:17:34,034 --> 00:17:36,827
ACTS AS BOTH AN ELECTRODE
FOR THE WELDING PROCESS
286
00:17:36,827 --> 00:17:40,068
AND AS FILLER MATERIAL.
287
00:17:40,068 --> 00:17:42,655
WITH THE INSIDE WELD COMPLETE,
288
00:17:42,655 --> 00:17:45,310
A SECOND WELDER DEVICE
WORKS ON THE OUTSIDE OF THE PIPE
289
00:17:45,310 --> 00:17:48,241
TO GIVE IT A DOUBLE-WELDED SEAM.
290
00:17:51,241 --> 00:17:55,482
A PLASMA TORCH CUTS THE PIPE
TO LENGTH CLEANLY BY MELTING IT.
291
00:17:55,482 --> 00:17:57,620
IN THIS CASE,
THEY'RE MAKING A WATER PIPE
292
00:17:57,620 --> 00:18:03,103
THAT'S 6 FEET IN DIAMETER
AND 50 FEET IN LENGTH.
293
00:18:03,103 --> 00:18:07,172
THE PIPE THEN ROLLS OVER
TO THE NEXT STATION.
294
00:18:09,310 --> 00:18:12,137
HERE, A WORKER GRINDS
BOTH ENDS OF THE PIPE
295
00:18:12,137 --> 00:18:14,034
TO IMPROVE THE PROFILE.
296
00:18:18,103 --> 00:18:20,379
THEN IT'S OVER TO A DIE.
297
00:18:20,379 --> 00:18:22,103
IT STRETCHES ONE END OF THE PIPE
298
00:18:22,103 --> 00:18:25,379
TO CREATE A SLIGHT FLARE,
OR BELL.
299
00:18:25,379 --> 00:18:27,896
THIS WILL ALLOW IT TO
BE CONNECTED TO THE NARROWER END
300
00:18:27,896 --> 00:18:32,068
OF ANOTHER PIPE, FORMING
WHAT'S KNOWN AS A LAP JOINT.
301
00:18:32,068 --> 00:18:34,310
NEXT, THEY CAP
THE ENDS OF THE PIPE
302
00:18:34,310 --> 00:18:37,931
AND PUMP IN WATER
TO A HIGHLY PRESSURIZED STATE.
303
00:18:37,931 --> 00:18:39,586
THEY LOOK FOR LEAKS IN THE WELD
304
00:18:39,586 --> 00:18:41,896
AND CONFIRM
THAT IT'S WATERTIGHT.
305
00:18:41,896 --> 00:18:45,482
ANOTHER WORKER INSTALLS RUBBER
DAMS AT BOTH ENDS OF THE PIPE.
306
00:18:51,137 --> 00:18:55,655
A CEMENT FIXTURE THEN FLOWS INTO
A LONG APPLICATOR WITH A NOZZLE.
307
00:18:58,068 --> 00:19:01,758
THE NOZZLE APPLIES THE CEMENT
TO THE PIPE'S INNER WALL
308
00:19:01,758 --> 00:19:04,931
AS THE PIPE SPINS AND GENERATES
A CENTRIFUGAL EFFECT
309
00:19:04,931 --> 00:19:07,724
THAT'S 70 TIMES
THE FORCE OF GRAVITY.
310
00:19:07,724 --> 00:19:11,206
THIS CAUSES THE CEMENT
TO BE DISTRIBUTED UNIFORMLY.
311
00:19:11,206 --> 00:19:15,689
THE RUBBER DAMS CONTAIN
THE CEMENT DURING THIS PROCESS.
312
00:19:15,689 --> 00:19:18,275
THE SPINNING DISPLACES WATER
IN THE CEMENT,
313
00:19:18,275 --> 00:19:22,241
AND A BLOWER FORCES THAT WATER
OUT OF THE PIPE.
314
00:19:22,241 --> 00:19:25,931
NEXT, A WORKER DRAPES PLASTIC
ONTO BOTH ENDS OF THE PIPE.
315
00:19:25,931 --> 00:19:28,586
HE TACKS IT WITH MAGNETS
316
00:19:28,586 --> 00:19:31,034
AND THEN SECURES IT TIGHTLY
WITH AN ELASTIC CORD.
317
00:19:33,827 --> 00:19:36,793
HE PUMPS HOT STEAM
INTO THE PIPE.
318
00:19:36,793 --> 00:19:42,103
OVER A PERIOD OF 18 HOURS,
THE STEAM CURES THE CEMENT.
319
00:19:42,103 --> 00:19:44,827
IT'S A SLOW CURE
FOR BETTER STRUCTURAL INTEGRITY.
320
00:19:44,827 --> 00:19:47,620
FOR OUR CAMERA,
THEY OPEN ONE END OF THE PIPE
321
00:19:47,620 --> 00:19:51,034
FOR AN INSIDE LOOK
AT THE STEAMING ACTION.
322
00:19:51,034 --> 00:19:54,724
18 HOURS LATER,
THEY REMOVE THE RUBBER DAMS.
323
00:19:54,724 --> 00:20:00,068
THE SPIRAL-WELDED PIPE NOW HAS
A TOUGH, PROTECTIVE INNER LINER.
324
00:20:00,068 --> 00:20:03,310
NEXT, THE PIPE MOVES INTO
A BLAST CHAMBER,
325
00:20:03,310 --> 00:20:06,379
WHERE FINE, STEEL SHOT
BOMBARDS THE OUTSIDE OF THE PIPE
326
00:20:06,379 --> 00:20:08,379
TO CLEAN IT THOROUGHLY.
327
00:20:08,379 --> 00:20:11,482
THIS PREPARES IT
FOR THE NEXT STEP.
328
00:20:13,310 --> 00:20:16,275
A SPRAYER APPLIES
A LIQUID ADHESIVE.
329
00:20:18,586 --> 00:20:21,896
OVER THE ADHESIVE, THEY WRAP
A POLYETHYLENE-BACKED TAPE.
330
00:20:23,965 --> 00:20:26,827
THEY APPLY
A TOTAL OF THREE LAYERS OF TAPE.
331
00:20:26,827 --> 00:20:29,724
THE FIRST ONE
PROVIDES CORROSION PROTECTION
332
00:20:29,724 --> 00:20:33,310
TO THE SPIRALLY WELDED STEEL.
333
00:20:33,310 --> 00:20:36,758
THE OTHER TWO LAYERS
PROTECT THE FIRST.
334
00:20:36,758 --> 00:20:41,689
THEY GIVE THE SPIRALLY WELDED
PIPE A TOUGH OUTER SKIN.
335
00:20:41,689 --> 00:20:44,482
THE THREE TAPES ARE COLOR-CODED.
336
00:20:44,482 --> 00:20:46,482
THIS WILL ALLOW
THE DEPTH OF ANY DAMAGE
337
00:20:46,482 --> 00:20:49,206
TO BE QUICKLY ASSESSED ON-SITE.
338
00:20:55,551 --> 00:20:59,310
THEY PRODUCE APPROXIMATELY
15 SPIRALLY WELDED WATER PIPES
339
00:20:59,310 --> 00:21:02,758
PER EIGHT-HOUR SHIFT
AT THIS FACTORY.
340
00:21:05,068 --> 00:21:09,689
THEY SHOULD LAST FOR A CENTURY
UNDERGROUND.
341
00:21:09,689 --> 00:21:12,689
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342
00:21:12,689 --> 00:21:15,689
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343
00:21:21,931 --> 00:21:23,965
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ABOUT THE SHOW,
344
00:21:23,965 --> 00:21:26,827
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345
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