NARRATOR: IN THE CITY WHERE SKYSCRAPERS RULE, ONE RESIDENT ARCHITECT HAS A DREAM-- TO STAMP HIS MARK ON THE MOST ICONIC SKYLINE ON EARTH WITH THE MOST DARING SKYSCRAPER IN GENERATIONS.

MAN: THIS IS RADICALLY SHATTERING WHAT A TALL, SLENDER SKYSCRAPER OF THE 21ST CENTURY COULD BE.

NARRATOR: THIS IS THE INSIDE STORY OF NEW YORK'S LATEST WONDER BUILDING, THE SKINNIEST SKYSCRAPER EVER TO BE CONSTRUCTED.

MAN: I DON'T THINK THERE IS ANOTHER SKYSCRAPER IN THE WORLD WHICH CAN COMPARE WITH IT.

NARRATOR: IN AN EXTRAORDINARY PROJECT, OLD AND NEW ARE MERGING TO FORM A BUILDING WITHIN A BUILDING.

MAN: THIS IS TRULY COMPLEX.

THERE IS A HUGE AMOUNT OF UNKNOWNS.

NARRATOR: BATTLING SOME OF THE HARDEST GROUND EVER FOUND BENEATH A MAJOR CITY.

MAN: SOMEBODY'S GONNA GET KILLED WALKING OVER THERE.

NARRATOR: ONE FALSE MOVE COULD TURN A CENTURY OF MANHATTAN HISTORY TO DUST.

NOTHING ON THIS JOB IS EASY.

EVERYTHING'S A PAIN IN THE ASS.

NARRATOR: THIS IS THE SKINNY SKYSCRAPER AND IT IS AN IMPOSSIBLE BUILD.

IMPOSSIBLE BUILDS WAS MADE POSSIBLE IN PART BY CONTRIBUTIONS TO YOUR PBS STATION FROM VIEWERS LIKE YOU.

THANK YOU.

MANHATTAN.

JUST 23 SQUARE MILES AND HOME TO SOME OF THE MOST REMARKABLE BUILDINGS EVER BUILT.

FOR MORE THAN A CENTURY, NEW YORK HAS BEEN PIONEERING THE SUPER HIGH-RISE.

THE RESULT--THE MOST ICONIC CITY SKYLINE ON EARTH.

NEW YORK IS THE PREMIER SKYSCRAPER CITY.

IT ALWAYS HAS BEEN.

WHERE PROFIT IS KING.

IT'S THE CAPITAL OF CAPITALISM.

WE HAVE A LONG HISTORY OF EXPLOITING THE VALUE OF THE LAND FOR A PROFIT.

NARRATOR: AFTER MORE THAN TWO CENTURIES OF CONTINUED DEVELOPMENT AND REDEVELOPMENT, MANHATTAN ISLAND IS JAMMED.

WITH SO LITTLE SPACE FOR CONSTRUCTION LEFT, ARCHITECTS ARE BEING FORCED TO REWRITE THE RULE BOOK.

THE SOLUTION HAS SPAWNED A NEW BREED OF SKYSCRAPER, STRUCTURES WHICH DWARF LAST CENTURY'S HIGH-RISE BUILDINGS AND TAKE UP JUST A FRACTION OF THE SPACE.

THEY'RE CALLED THE SUPER-TALL.

WILLIS: THESE NEW TOWERS INVENT A REALLY NEW TYPE OF SKYSCRAPER IN SKYSCRAPER HISTORY.

THEY BECOME THE LANDMARKS OF THE FUTURE BECAUSE THEY REPRESENT THE INVENTION OF THE EARLY 21ST CENTURY.

NARRATOR: BUT THE NEWEST KID ON THE BLOCK 111 WEST 57TH STREET, WILL BE TALLER AND NARROWER THAN ANY OTHER SKYSCRAPER IN THE WORLD-- OVER 1,400 FEET TALL AND JUST 60 FEET WIDE.

IF THE TEAM BEHIND ITS CUTTING-EDGE DESIGN CAN PULL IT OFF, THEN LEAD ARCHITECT AND LOCAL BOY GREGG PASQUARELLI WILL BE FULFILLING A CHILDHOOD DREAM.

WHEN I WAS A LITTLE BOY GROWING UP IN QUEENS, FROM MY BEDROOM I COULD WATCH THE ORIGINAL WORLD TRADE CENTER BEING CONSTRUCTED.

AND I KEPT A LITTLE LEGO MODEL ON MY DESK AND I FOLLOWED THE TRADE CENTER CONSTRUCTION GOING UP AND I'D LOOK OUT THE WINDOW AND SEE IT EVERY DAY.

SO, TO BE A BORN AND RAISED NEW YORKER AND GET TO WORK ON AN EXTRAORDINARY BUILDING IS AN ABSOLUTE DREAM COME TRUE.

NARRATOR: GREGG HAS SPENT 20 YEARS DESIGNING INNOVATIVE BUILDINGS, BUT NOTHING QUITE LIKE 111 WEST 57TH STREET.

YOU HAVE TO TAKE A LEAP OF FAITH.

YOU HAVE TO TRUST THAT YOU'RE GOING TO GO INTO UNKNOWN TERRITORY.

BUT THAT'S ALSO ONE OF THE MOST EXCITING THINGS YOU CAN DO AS AN ARCHITECT.

NARRATOR: BUT REALIZING NEW YORK'S NEWEST SKYSCRAPER WILL NOT BE EASY.

EARLY HIGH-RISES WERE BUILT ON PLOTS THAT CONSUMED ENTIRE CITY BLOCKS.

THIS SUPER-TALL MUST FIT ONTO A PLOT THAT'S JUST 80 FEET BY 60 FEET, LITTLE BIGGER THAN A BASKETBALL COURT.

PASQUARELLI: THIS SKYSCRAPER IS ALL ABOUT DENSITY.

IT'S ALL ABOUT TAKING THE SQUARE FEET THAT ARE ALLOWED TO BE BUILT AND PUTTING IT TALL AND HIGH WITH GREAT VIEWS IN THE MIDDLE OF ONE OF THE DENSEST PARTS OF OUR COUNTRY.

NARRATOR: THE PLOT FOR THE SKYSCRAPER IS LOCATED IN MIDTOWN MANHATTAN, ON WEST 57TH STREET.

KNOWN AS BILLIONAIRES' ROW, SKY-HIGH APARTMENTS HERE BOAST UNOBSTRUCTED VIEWS OVER CENTRAL PARK AND COMMAND ASTRONOMICAL PRICE TAGS.

THIS IS SOME OF THE MOST EXPENSIVE LAND ON THE PLANET, AND THE ONLY WAY TO MAKE A PROFIT HERE IS TO BUILD TALL.

PASQUARELLI: A VIEW OF CENTRAL PARK IS ABSOLUTELY THE MAIN DRIVER OF THE BUILDING AND OF ALL OF THESE SUPER-TALLS THAT YOU SEE GOING UP.

IT'S SUCH A PRIVILEGE TO HAVE THAT VIEW OF THE PARK AND IT'S SO DIFFICULT TO GET, AND THERE ARE SO FEW PLACES TO CONTINUE TO BUILD IN NEW YORK CITY THAT IT'S REALLY QUITE A RARE AND SPECIAL QUALITY FOR ANY APARTMENT.

NARRATOR: THE PLOT SITS TWO STREETS BACK FROM THE PARK.

THE PROBLEM IS, NO ONE HAS EVER BUILT A SKYSCRAPER IN SUCH A SMALL SPACE... BECAUSE TALL BUILDINGS NEED WIDE SUPPORTING FOUNDATIONS.

THAT'S THE REASON THIS PLOT LAID EMPTY FOR DECADES.

THAT WAS, UNTIL A LUXURY REAL ESTATE DEVELOPMENT FIRM TOOK A MULTI-MILLION-DOLLAR GAMBLE AND BOUGHT IT.

THIS LOT THAT WE'RE STANDING ON WAS FOR SALE AND THEN SOLD AND THEN CHANGED HANDS PROBABLY HALF A DOZEN TIMES OVER THE 10 YEARS PRIOR TO WHEN WE HELD IT, AND ALL LOOKED AT IT SAYING EITHER THEY DIDN'T KNOW HOW TO DO IT OR THEY KNEW WHAT HAD TO BE DONE BUT THEY DIDN'T THINK THEY COULD.

NARRATOR: THE DEVELOPERS AND ARCHITECTS NOW THINK THEY HAVE THE SOLUTION.

IT MEANT BUYING THE PLOT IN THE BUILDING NEXT DOOR FOR AN EYE-WATERING $177 MILLION.

IT'S NOT SIMPLY A CASE OF KNOCKING DOWN THE NEIGHBORING BUILDING AND INCREASING THE PLOT SIZE, BECAUSE THIS IS STEINWAY HALL AND IT'S HERE TO STAY.

COMPLETED IN 1924 TO HOUSE THE SHOWROOMS AND CONCERT HALLS OF THE WORLD-FAMOUS STEINWAY PIANOS, THE BUILDING NOW HAS LANDMARK STATUS AND THAT MEANS IT CAN'T BE DEMOLISHED.

THE SOLUTION IS TO SEAMLESSLY MERGE THE OLD AND NEW, TO RESTORE STEINWAY HALL WHILE INTEGRATING A BRAND-NEW SKYSCRAPER WITHIN THE ORIGINAL FOUNDATIONS.

PASQUARELLI: IT'S ABSOLUTELY A CRAZY PROJECT.

I MEAN, THIS IS A BUILDING THAT'S 1,428 FEET TALL.

I MEAN, IT'S A COUPLE HUNDRED FEET TALLER THAN THE EMPIRE STATE BUILDING.

NARRATOR: IF THE TINY PLOT IS TO SUPPORT WHAT WILL BE THE CITY'S TALLEST RESIDENTIAL BUILDING, THE CONSTRUCTION TEAM ARE GOING TO HAVE TO BUILD UNDER STEINWAY HALL.

YOU CAN SEE WHERE THE HISTORIC BUILDING SAT, AND BY INTEGRATING THE FOUNDATIONS OF BOTH THE OLD BUILDING AND THE NEW BUILDING, WE'RE ABLE TO BUILD A BUILDING FAR TALLER THAN ANYONE EVER THOUGHT WAS POSSIBLE ON THIS PARTICULAR PLOT.

NARRATOR: AT STREET LEVEL, A SOON-TO-BE-RESTORED STEINWAY HALL WILL SET THE TONE.

BUT SOARING ABOVE THE HISTORIC 20TH-CENTURY BUILDING WILL BE A VERY 21ST-CENTURY TOWER.

INSIDE, JUST 60 EXCLUSIVE APARTMENTS.

THE MOST EXPENSIVE WILL SET THE POTENTIAL BUYER BACK $57 MILLION.

PASQUARELLI: THE VIEWS WILL BE ABSOLUTELY SPECTACULAR.

I MEAN, ONCE YOU CLEAR THE HISTORIC BUILDING, THERE ARE ONLY OTHER SORT OF LOW 20-SOMETHING-STORY BUILDINGS IN THE WAY.

SO, FROM THIS POINT ON, THE VIEW OF CENTRAL PARK, YOU'RE DEAD CENTER ON THE PARK AND YOU HAVE AN UNOBSTRUCTED VIEW AND OBVIOUSLY, AS YOU GET HIGHER AND HIGHER IN THE BUILDING, YOU CLEAR MOST OF THE OTHER BUILDINGS IN MANHATTAN AND YOU CAN SEE FROM THE MOUNTAINS 50 TO 75 MILES NORTH OUT TO THE ATLANTIC OCEAN.

NARRATOR: ALMOST A QUARTER OF A MILE TALL, THE DARING DESIGN WILL PAY HOMAGE TO THE SKYSCRAPERS OF YESTERYEAR.

FOR LEAD ARCHITECT GREGG PASQUARELLI, THE BUILDING WILL BE A LEGACY TO THE CITY HE LOVES.

PASQUARELLI: WORKING IN MANHATTAN IS AN ABSOLUTE ARCHITECT'S DREAM.

I MEAN, HERE ON ONE SMALL ISLAND, YOU CAN SEE EVERY PERIOD OF ARCHITECTURE OF THE LAST 200 YEARS AND YOU CAN REALLY SEE THE EMERGENCE OF THE SKYSCRAPER, THE WAY IT'S BEEN THOUGHT ABOUT AND DESIGNED AND DEVELOPED OVER THE PAST CENTURY, AND, YOU KNOW, IT'S CHALLENGING BECAUSE SOME OF THE BEST ARCHITECTS IN THE WORLD HAVE BUILT INCREDIBLE BUILDINGS HERE, AND WHEN YOU KNOW YOU'RE GOING TO ADD ANOTHER ONE TO THE SKYLINE AND TO THE COLLECTION, THE BAR IS SET HIGH.

NARRATOR: THE DESIGN MAY BE SET, BUT THE POSTAGE STAMP-SIZED PLOT, THE PROTECTED BUILDING, AND THE EXTREME PROPORTIONS OF THE SKYSCRAPER MEAN TO BUILD IT, THE TEAM MUST NOW BECOME CONSTRUCTION PIONEERS, AND THERE ARE STILL NO GUARANTEES THE DESIGN ACTUALLY WORKS.

AFTER ALL THE THOUSANDS OF HOURS THAT WE'VE SPENT WORKING ON THE PROJECT, OF COURSE, THE WORST THING THAT WOULD HAPPEN IS WE FIND OUT WE CAN'T MAKE IT WORK STRUCTURALLY.

IF WE MESS THIS ONE UP, I MEAN, IT'S NOT LIKE ANYONE'S GONNA NOTICE, SO, THAT'S OK. NARRATOR: MAY 2015, AND ON NEW YORK'S WEST 57TH STREET, WORK ON THE SKINNY SKYSCRAPER IS UNDERWAY.

THE MAN TASKED WITH MAKING THE CUTTING-EDGE DESIGN A REALITY IS PROJECT SUPERINTENDENT ANTHONY VIVELO.

WE'RE BUILDING A 1,400-AND-SOME-ODD-FOOT STRUCTURE.

RESIDENTIAL.

HIGH-END.

STICK IN THE SKY.

IT IS A LITTLE SKINNY ON TOP AND IT'S GONNA RISE ABOVE EVERYTHING AROUND YOU.

HEY!

NARRATOR: DESPITE HIS 30 YEARS' INDUSTRY EXPERIENCE... [BEEP] TOO MUCH [INDISTINCT] THERE.

NARRATOR: NOTHING COULD PREPARE ANTHONY FOR HIS LATEST PROJECT.

VIVELO: WE'RE BUILDING IT ON A FOOTPRINT THIS SMALL.

TO BUILD 1,400, 1,500 FEET UP IN THIS SMALL AMOUNT OF AREA IS A LOGISTICAL NIGHTMARE.

NARRATOR: THE CRAMPED SITE ISN'T THE ONLY ISSUE WITH THE PROJECT.

THE VERY FIRST JOB, DIGGING OUT THE FOUNDATION, MEANS WORKING UNDERGROUND.

MORE SPECIFICALLY, UNDER THE NEAR-CENTURY-OLD STEINWAY HALL.

THIS MEANS REMOVING THOUSANDS OF CUBIC FEET OF EARTH AND ROCK WITHOUT DAMAGING THE PROTECTED BUILDING ABOVE.

VIVELO: EVERYBODY IN THE TEAM WORKS AND HELPS OUT EACH OTHER.

THAT'S THE ONLY WAY WE'LL GET THROUGH THIS.

IF WE'RE NOT WORKING COHESIVELY TOGETHER, THIS'LL NEVER GET BUILT.

NARRATOR: WHEN THE DEEP FOUNDATIONS HAVE EVENTUALLY BEEN DUG, THE TEAM WILL NEED TO FILL IN THE HOLE, BUT THIS TIME WITH A REINFORCED STEEL FOUNDATION SYSTEM FILLED WITH 6,000 CUBIC YARDS OF CONCRETE.

THE TEAM HAS JUST 6 MONTHS TO COMPLETE THIS QUITE LITERALLY GROUNDBREAKING STAGE OF CONSTRUCTION.

MAN: THIS DRIVES THE ENTIRE SCHEDULE FOR THE ENTIRE PROJECT.

WITHOUT DRILLING, BREAKING ROCK, AND GETTING TO GOOD SUITABLE ROCK CONDITIONS, WE CAN'T BUILD A FOUNDATION, WE CAN'T BUILD SUPERSTRUCTURE, AND OBVIOUSLY, WE CAN'T FINISH THE BUILDING COMING THROUGH STEINWAY.

NARRATOR: BUT JOHN SZEKALSKI AND HIS TEAM OF DIGGERS AND DRILLERS HAVE A HUGE CHALLENGE ON THEIR HANDS.

IF WORKING IN THE CRAMPED SUBCELLAR ISN'T BACK-BREAKING ENOUGH, THE GROUND THEY'RE DIGGING OUT ADDS A WHOLE OTHER LEVEL OF COMPLEXITY.

MANHATTAN IS BUILT ON SOLID GRANITE BEDROCK.

NORMALLY FOUND DEEP UNDERGROUND, HERE IT RISES TO THE SURFACE.

IT'S THE VERY REASON NEW YORK BECAME THE HOME OF THE SKYSCRAPER, BUT NO ONE HAS EVER STARTED TO BUILD ONE FROM ANOTHER BUILDING'S BASEMENT.

SZEKALSKI: IT'S BEEN CHALLENGING BECAUSE OF THE LOW HEADROOM SPACE, THE SMALLER EQUIPMENT THAT WE'RE USING IN THIS AREA, AND IT'S TOUGH, IT'S TIME-CONSUMING, AND IT'S REALLY TEDIOUS.

NARRATOR: AS JOHN'S TEAM CHIP AWAY AT THE GRANITE BEDROCK, STEINWAY HALL'S ORIGINAL FOUNDATIONS ARE SLOWLY EXPOSED.

THE CHALLENGE NOW IS TO KEEP THE PROJECT ON TRACK WITHOUT DAMAGING THE HISTORIC BUILDING OVERHEAD.

AND JUST FEET ABOVE THE CONSTRUCTION IS THE HALL'S MOST PRIZED FEATURE...

THE ROTUNDA, STEINWAY HALL'S LAVISH CONCERT SPACE.

LINED WITH ITALIAN MARBLE AND BOASTING A SPECTACULAR, HAND-PAINTED CEILING, IT WAS CONCEIVED BY THE ARCHITECTS BEHIND NEW YORK'S ICONIC GRAND CENTRAL STATION.

THE ROOM ITSELF, AS WELL AS THE BUILDING AROUND IT, HAS EARNED LANDMARK STATUS.

BUT BY 2015, THE ONLY THINGS HOLDING IT UP ARE STILTS, ALMOST 100 YEARS OLD.

MAN: THESE ARE THE EXISTING COLUMNS FOR THE STEINWAY BUILDING, THE LANDMARK STEINWAY BUILDING, THAT CAN'T BE DISTURBED BECAUSE THEY'RE HOLDING UP THE BUILDING THAT WE'RE BUILDING THROUGH.

THEY'RE DRILLING THE ROCK, IT WOULD SLIP, AND YOU WOULD END UP CRACKING WALLS, COLUMNS, FLOOR SLABS.

THIS MAKES IT A HARD BUILD.

[DRILL WHIRRING] NARRATOR: WHEN THE FOUNDATIONS ARE EVENTUALLY COMPLETE, THEY WILL SUPPORT A SKYSCRAPER THAT STANDS HIGHER THAN THE EMPIRE STATE BUILDING, BUT INCREDIBLY, THE MODERN-DAY MASTERPIECE WILL OCCUPY JUST 1/16 OF THE SPACE.

SO, THIS IS RADICALLY SHATTERING AND PUSHING US FORWARD IN THE DESIGN AND CONSTRUCTION AND AESTHETICS OF WHAT A TALL, SLENDER SKYSCRAPER OF THE 21ST CENTURY COULD BE.

NARRATOR: THE DRAMATIC DIMENSIONS OF THE SKYSCRAPER REQUIRE IMMENSE INTERNAL STRENGTH TO STOP IT FROM BLOWING OVER IN THE WIND.

THE TRADITIONAL METHOD IS TO HAVE VERTICAL SUPPORT COLUMNS RUNNING THROUGH ALL FLOORS, BUT THIS WOULD TAKE UP PRECIOUS FLOOR SPACE IN THE SKINNY SKYSCRAPER.

THE ARCHITECTS' REVOLUTIONARY SOLUTION IS TWO 1,400-FOOT SHEER WALLS.

TOGETHER, THEY WILL FORM TWO SOLID SIDES OF THE BUILDING, HOPEFULLY PROVIDING THE RIGIDITY THE DESIGN DEMANDS.

PASQUARELLI: THIS HAS NEVER BEEN DONE AT THIS SCALE.

SO, IT'S UNUSUAL IN THAT SENSE THAT IT'S VERY, VERY DENSE IN STRUCTURE ON TWO OF THE WALLS AND VERY OPEN AND DEVOID OF STRUCTURE ON TWO OF THE WALLS, AND THAT REALLY SET UP THE AESTHETIC OF THE BUILDING AS A WHOLE.

[HAMMERING] NARRATOR: TO FIND OUT IF THE DESIGN DOES HAVE THE STRENGTH TO FEND OFF THE ELEMENTS, THE ARCHITECTS HAVE TURNED TO A GROUP OF ENGINEERS...

THEY PROBABLY WANT TO BLOCK IT OUT AS MUCH AS POSSIBLE.

NARRATOR: WHO HAVE THE KNOW-HOW TO TAME THE FORCES OF NATURE.

MAN: WHAT WE DO HERE IS LOOK AT THE DESIGN OF THE BUILDING AND HOW IT RESPONDS IN THE WIND, AND TO DO THAT, WE BUILD A SCALE MODEL OF THE BUILDING AND ITS SURROUNDINGS AND TEST IT IN A WIND TUNNEL.

NARRATOR: THIS MULTI-MILLION-DOLLAR FACILITY, LOCATED IN TORONTO, CANADA, SIMULATES HOW WIND AFFECTS THE STABILITY OF SUPER-TALL BUILDINGS.

IT'S THE ULTIMATE PROVING GROUND FOR THE SKYSCRAPERS OF TOMORROW, AND IT'S WHERE THE DREAMS OF ARCHITECTS AND STRUCTURAL ENGINEERS ARE MADE OR BROKEN.

WE'RE THE BAD GUYS HERE.

WE'RE DELIVERING BAD NEWS.

BUT IT'S PART OF THE PROCESS AND WE COME UP WITH A SOLUTION AND REALLY MAKE THESE THINGS POSSIBLE.

SO, HERE WE ARE.

THIS IS NEW YORK CITY AND WE ARE PREPARING TO DO A SIMULATION TEST ON OUR STUDY MODEL.

NARRATOR: INSIDE THE FOAM TEST MODEL ARE 1,024 PRESSURE PADS.

EACH ONE RECORDS WIND BLOWS AT A DIFFERENT POINT ON THE BUILDING.

♪ MAN: SO, WE'RE LOOKING AT THE WINDS CLOSER TO GROUND, AROUND THE TOP OF THE BUILDINGS, JUST AT THE SOUTH SIDE OF CENTRAL PARK.

AS WE RAISE THE HEIGHT, START TO SEE THE SMOKE PICK UP IN SPEED.

WELL, THAT'S--THAT MODELS THE NATURAL WIND VERY WELL.

AS WE INCREASE IN HEIGHT, THE WIND SPEED INCREASES, SO, THE PRESSURES THEMSELVES INCREASE QUITE SUBSTANTIALLY AS WE COME UP IN HEIGHT.

SO, THAT'S WHAT MAKES TALL BUILDINGS MORE SUSCEPTIBLE TO WIND.

NARRATOR: AT THE BASE OF THE TOWER, THE SURROUNDING BUILDINGS SHELTER THE LOWER FLOORS FROM THE WIND.

BUT AT THE VERY TOP, A QUARTER OF A MILE ABOVE, THE IN-BUILT SENSORS HAVE DETECTED A SERIOUS PROBLEM.

THE WIND IS CAUSING THE TOP OF THE TOWER TO MOVE.

IT MAY BE UNDETECTABLE TO THE NAKED EYE ON THIS MODEL, BUT SCALED UP 500 TIMES TO FULL SIZE, THE LEVEL OF MOVEMENT WOULD BE MULTIPLIED TO FEET.

FOR ANYONE INSIDE, THAT WOULD BE TERRIFYING.

YES, WE BRING SOME ISSUES ONTO THE PROJECT, SOME INFORMATION THAT SOMETIMES IS HARD TO HEAR, BUT WE'RE PART OF REDEFINING WHAT'S POSSIBLE.

NARRATOR: THE SOLUTION IS DRASTIC.

3 FLOORS OF PLANNED LUXURY LIVING SPACE WILL BE SACRIFICED.

INSTEAD, THEY'LL BE LEFT OPEN, ALLOWING THE WIND TO PASS THROUGH THE STRUCTURE.

IT'S A COSTLY COMPROMISE, BUT IT'S THE ONLY WAY THE ENGINEERS CAN HELP STOP THE SKINNY SKYSCRAPER FROM SWAYING.

SEPTEMBER 2015.

YOU THINK YOU'LL BE DONE TODAY?

MAN: OH, YEAH, SURE.

NARRATOR: EXCAVATION OF THE SKINNY SKYSCRAPER'S FOUNDATIONS HAVE FINALLY REACHED THEIR OPTIMUM LEVEL, AT 50 FEET BELOW STREET LEVEL.

THE NEXT STAGE IS INSTALLING ONE OF THE MOST CRITICAL COMPONENTS TO ANY SKYSCRAPER.

ROCK ANCHORS--HIGH-TENSION STEEL BARS DESIGNED TO KEEP SUPER-TALL BUILDINGS FIRMLY ATTACHED TO THE GROUND.

SO, THIS BUILDING'S VERY SLENDER.

IT HAS A VERY SMALL FOOTPRINT AND IT'S VERY TALL.

SO, WHEN YOU HAVE A SMALL FOOTPRINT AND A VERY TALL BUILDING, THE LOAD'S MUCH GREATER THAN IF YOU HAD A WIDER BASE.

NARRATOR: TO LOCK THIS SKYSCRAPER TO THE BEDROCK, ITS WEIGHT IS DISTRIBUTED ACROSS 200 ANCHORS.

EACH ANCHOR WILL BE STRETCHED LIKE A RUBBER BAND IN TENSION, PROVIDING A DOWNWARD FORCE OF 300 TONS.

WITH ALL 200 ANCHORS INSTALLED, 60,000 TONS OF DOWNWARD FORCE WILL HELP HOLD THE SKYSCRAPER STEADY, EVEN AGAINST HURRICANE-FORCE WIND.

THE BUILDING'S SMALL FOOTPRINT MEANS THE ROCK ANCHORS ARE MORE TIGHTLY PACKED THAN ON ANY OTHER SKYSCRAPER.

INSTALLATION IS TAKING FAR LONGER THAN EXPECTED, BUT THIS IS ONE JOB THAT CANNOT BE RUSHED.

VIVELO: IF SOMETHING'S WRONG HERE, IT'S GONNA MULTIPLY TENFOLD UP ABOVE.

SO, EVERYTHING DOWN HERE HAS TO BE PERFECT.

WE HAVE TO GET THIS RIGHT SO THE REST OF THE BUILDING GOES RIGHT.

NARRATOR: IT'S MARCH 2016.

THE SKINNY SKYSCRAPER HAS BEEN UNDER CONSTRUCTION FOR MORE THAN TWO YEARS.

THE BUILDING HAS YET TO RISE ABOVE GROUND LEVEL, BUT THE PUNISHING EXCAVATION WORK IS NOW COMPLETE.

IT'S TAKEN 4 MONTHS LONGER THAN SCHEDULED, BUT CRUCIALLY, ALL THE ROCK ANCHORS ARE IN PLACE.

STEINWAY HALL'S OLD FOUNDATION COLUMNS HAVE BEEN STRENGTHENED AND SHORED UP, SO, THE SKINNY SKYSCRAPER AT LAST HAS THE SOLID BASE IT NEEDS TO SOAR.

PASQUARELLI: TO BUILD AND PLACE ALL THAT REBAR AND PUT ALL THOSE CONCRETE WALLS INSIDE A HISTORIC STRUCTURE IS AN INCREDIBLE CHALLENGE, AND WE JUST REALLY FEEL WONDERFUL ABOUT GETTING TO THIS POINT.

NARRATOR: WITH THE COMPLEX FOUNDATION NOW COMPLETE... WHAT'S THE PROBLEM?

NARRATOR: PROJECT SUPERINTENDENT ANTHONY VIVELO...

ROB [INDISTINCT].

WHERE ARE YOU, ROB?

NARRATOR: CAN FINALLY START TO GO VERTICAL.

TODAY, HIS TEAM WILL ATTEMPT THE CONCRETE POUR, COMPLETING THE FIRST FLOOR OF THE 82-STORY SKYSCRAPER.

ANY ISSUES, COME SEE ME.

WELL, NOW WE'RE ABOVE GROUND.

WE'VE BEEN IN A HOLE FOR TWO YEARS NOW.

WE'VE ENCOUNTERED THE HARDEST BEDROCK IN NEW YORK CITY.

NOT BY MY WORDS.

MY ENGINEERS HAVE BEEN AROUND FOR 30 OR 40 YEARS.

EVERYTHING WE'RE DOING HERE IS GROUNDBREAKING.

IT'S RIDICULOUS, IT'S HARD.

THE FIRST FLOOR WAS DEFINITELY A BIG DEAL TO EVERYBODY.

IMPORTANT.

NARRATOR: THE FLOOR AREA OF THE SKINNY SKYSCRAPER MAY BE SMALL, BUT THAT ONLY MAKES ANTHONY'S JOB EVEN MORE COMPLEX.

FROM THIS WALL HERE TO ABOUT 20 FEET BACK AFTER THAT, THAT'S IT.

THERE'S ABOUT 12 OR 13 DIFFERENT ELEVATIONS JUST IN HERE.

MOST SLABS ARE FLAT.

THERE'S SO MANY DIFFERENT ELEVATIONS.

NOTHING EASY.

NOTHING ON THIS JOB IS EASY.

EVERYTHING'S A PAIN IN THE ASS.

NARRATOR: TODAY'S POUR WILL REQUIRE NEARLY 400 TONS OF SUPER-HIGH-STRENGTH CONCRETE AND ONCE IT STARTS FLOWING, IT CAN'T BE STOPPED.

THE CONCRETE MUST SET AS ONE SINGLE MASS OR ELSE WEAKNESSES WILL FORM, AND THAT WILL COMPROMISE ITS OVERALL STRENGTH.

WITH MINUTES TO GO BEFORE THE FIRST TRUCK ARRIVES, ANTHONY ORDERS HIS TEAM TO CONDUCT A FINAL CHECK OF THE FORMWORK PANELS THAT WILL HOLD THE LIQUID CONCRETE IN PLACE AS IT HARDENS.

DEFINITELY THE HARDEST CONCRETE I'VE EVER HAD TO DEAL WITH.

IT'S ACTUALLY VERY THIN.

IT SPREADS OUT REAL QUICK, REAL EASY, BUT IT GETS THROUGH ALL THE CRACKS, SO, YOU COULD HAVE BLOWOUTS, A LOT OF LEAKAGE.

IF WE HAVE A LEAK, WE'RE [BEEP], GUYS.

YOU KNOW THAT, RIGHT?

IF A LEAK HAPPENS, WE GOTTA JUMP ON IT RIGHT AWAY, STOP THE LEAK, OR ELSE IT'LL SLOW PRODUCTION DOWN AND MAKE US EVEN GO FURTHER OUT OF TIME.

NARRATOR: AT 9 A.M., THE FIRST OF 19 CONCRETE TRUCKS PULLS UP BEHIND THE BUILDING ON WEST 58TH STREET.

THE POUR BEGINS RIGHT ON SCHEDULE.

GOT A NICE FLOW GOING HERE.

A LITTLE WET BUT IT'S MOVING.

SO FAR, SO GOOD.

EVERYTHING'S GOING SMOOTHLY.

WE'RE IN GOOD SHAPE RIGHT NOW.

UNFORTUNATELY, THAT COULD CHANGE AT ANY MOMENT, SO, I GOT MY FINGERS CROSSED.

♪ NARRATOR: ON THE STREET OUTSIDE, AS ONE TRUCK EMPTIES... ANOTHER PULLS UP.

IT'S A FINELY TUNED OPERATION, AND BY 2 P.M., THE POUR IS 2/3 OF THE WAY THROUGH.

VIVELO: RIGHT NOW, WE'RE PUMPING TRUCK NUMBER 12.

THAT'S 120 YARDS.

AND WE'RE GONNA CONTINUE POURING TO ABOUT 190 YARDS.

THAT'S 7 MORE TRUCKS.

I CAN'T LIE, I'M--OH, EASY, NOW.

STARTING TO GET HAPPY.

♪ EVERYTHING'S GOING ALL RIGHT?

[INAUDIBLE] NARRATOR: ANTHONY IS NOW TANTALIZINGLY CLOSE TO ACHIEVING A PIVOTAL STAGE IN THIS PIONEERING BUILD.

VIVELO: THIS IS TRUCK NUMBER 14.

WE SHOULD HAVE ABOUT 4, 5 MORE TO GO.

NARRATOR: AS ANTHONY COUNTS DOWN TRUCKS ON THE STREET OUTSIDE... 15.

NARRATOR: INSIDE... NARRATOR: HIS WORST NIGHTMARE IS BECOMING A REALITY.

[MEN SHOUTING INDISTINCTLY] NARRATOR: THERE'S A LEAK IN THE FORMWORK AND THE SUPER-HARD CONCRETE MIX IS POURING OUT AND HAS BEEN FOR SOME TIME.

MAN: CAN YOU TELL ME-- VIVELO: NOT NOW.

PLEASE.

I'M ABOUT TO LOSE MY [BEEP].

YEAH, IT'S A DISASTER.

HOLY [BEEP].

NARRATOR: HALF A TRUCKLOAD OF CONCRETE HAS FLOODED ONTO THE BASEMENT FLOOR.

VIVELO: YOU GUYS DIDN'T NOTICE THIS?

WHO'S WATCHING THIS THING?

NARRATOR: SOMEONE WASN'T PAYING ATTENTION AND ANTHONY'S ON THE WARPATH.

VIVELO: HOW DOES THIS HAPPEN, THAT NOBODY NOTICES IT?

THERE'S 5 YARDS ON THE GROUND.

NOBODY SAW IT LEAKING?

[BEEP] JOKE.

NARRATOR: OUTSIDE, THE TRUCKS PILE UP, WAITING TO DELIVER THEIR TIME-SENSITIVE LOADS.

BUT NOT A DROP MORE CAN BE POURED UNTIL THE LEAK IS FIXED AND THE RIVER OF CONCRETE CLEANED UP BEFORE IT SETS HARD.

VIVELO: [BEEP] AMATEUR HOUR!

NARRATOR: IT'S A HOUR BEFORE THE LEAK IS FIXED.

THE MESS IS CLEARED UP AND THE POUR RESUMES.

GOOD!

NARRATOR: 8 HOURS AFTER THE POUR BEGAN AND THE LAST DROP OF CONCRETE IS POURED.

I FEEL RELIEVED.

I'M SO GRATEFUL THAT IT'S DONE.

NARRATOR: IT WASN'T ALL SMOOTH SAILING FOR ANTHONY BUT A CRUCIAL STAGE IN THE CREATION OF NEW YORK'S LATEST SKYSCRAPER IS FINALLY COMPLETE.

VIVELO: WE FINALLY MADE IT UP TO THE FIRST-FLOOR SLAB AFTER A LONG, GRUELING SUBGRADE AND FOUNDATION WORK.

IT'S GONNA BE NICE TO WALK ON THIS AND WE'RE GOING UP AND WE'RE GONNA GO UP FAST.

HOPEFULLY, IT'S A LITTLE EASIER.

NARRATOR: OVER THE NEXT FEW MONTHS, THE SKINNY SKYSCRAPER BEGINS TO RISE BESIDE STEINWAY HALL.

AND THE ARCHITECTS HAVE AN IDEA THAT THEY'RE HOPING WILL ENSURE THEIR TOWER BECOMES AS ICONIC AS NEW YORK'S BEST-LOVED SKYSCRAPERS.

THEIR SECRET WEAPON IS TERRA COTTA.

PASQUARELLI: WE WANTED TO TAKE THAT DNA OF THOSE HISTORICAL MATERIALS, LIKE TERRA COTTA, AND USE THEM IN A NEW WAY THAT STRIKES A SILHOUETTE IN THE SKY, THAT YOU KNOW YOU'RE IN NEW YORK BUT YOU'VE NEVER SEEN A BUILDING LIKE THIS BEFORE.

NARRATOR: GLAZED TERRA COTTA FIRST APPEARED ON THE OUTSIDE OF BUILDINGS BACK IN THE LATE 1800S.

STRONG, FIREPROOF, AND EASILY MOLDED, IT WAS USED TO DECORATE SOME OF NEW YORK'S MOST ICONIC LANDMARKS, BUT EACH TILE HAD TO BE HANDMADE, AND THAT TOOK PRECIOUS TIME.

NOW WITH THE ADVANCEMENT IN MANUFACTURING TECHNIQUES, THE ARCHITECTS BELIEVE THE TIME IS RIGHT FOR TERRA COTTA TO MAKE A DRAMATIC COMEBACK.

[INAUDIBLE] WE WANT TO USE THESE MATERIALS BECAUSE THEY--THEY'RE TIMELESS.

BUT HOW DO WE MAKE THEM OF OUR TIME?

THIS IS OUR REAL SHOT.

WE DON'T WANT TO SCREW IT UP.

NARRATOR: A WORLDWIDE SEARCH FOR A COMPANY WITH THE EXPERTISE TO COVER AN ENTIRE SKYSCRAPER WITH TERRA COTTA LED THE ARCHITECTS TO NORTHWEST GERMANY.

LOCATED CLOSE TO THE BANKS OF THE RIVER RHINE, THIS SMALL, RURAL FACTORY IS ABOUT TO STAMP ITS MARK ON ONE OF THE MOST REMARKABLE BUILDINGS EVER CONSTRUCTED.

FOR OUR WORKERS, IT'S A VERY, VERY BIG ACHIEVEMENT TO WORK ON SUCH AN IMPORTANT PROJECT.

THEY WILL SEE IT ON THE NEWS.

THEY WILL SEE IT ON THE TV.

AND THEY WILL REMIND THEMSELVES THAT THEY HAVE WORKED ON THIS PARTICULAR BUILDING AND THEY WILL SEE THE TILES WHICH THEY ACTUALLY HAD IN THEIR HANDS.

NARRATOR: FOR THE PAST TWO DECADES, KLAUS BAYER AND HIS TEAM HAVE BEEN PUSHING TERRA COTTA INTO THE 21ST CENTURY.

THEIR SECRET FORMULA NOW ALLOWS THEM TO PRODUCE INTRICATELY SHAPED TILES FOR THE OUTSIDES OF BUILDINGS THAT ARE LARGER AND STRONGER THAN EVER BEFORE.

AND KEY FOR A SKYSCRAPER, THEY'RE ALMOST IMMUNE TO DIRT.

BAYER: THIS IS ONE OF THE ORIGINAL TILES WHICH WE ARE USING ON THE SKINNY SKYSCRAPER.

AS YOU CAN SEE, THIS TILE HAS QUITE A COMPLEX FORM.

IF YOU LOOK TO THESE KIND OF SHAPES, MIGHT BE FOR MANY, MANY PEOPLE AN UNDOABLE SHAPE.

FOR US AS A COMPANY, WE ARE USED TO WORK WITH THESE KIND OF SHAPES, AND THIS WAS ALSO THE BEAUTY FOR THE ARCHITECT.

HE COULD TALK TO US AND COULD DEVELOP THIS KIND OF SHAPES WITH US AND WE COULD HELP HIM TO GET HIS IDEA REALLY REALIZED.

NARRATOR: THE CERAMIC TILES PRODUCED BY KLAUS AND HIS TEAM OF 260 CRAFTSMEN CAN NOW BE FOUND CLADDING EXTRAORDINARY BUILDINGS AROUND THE WORLD.

BUT THE SKINNY SKYSCRAPER WILL BE THEIR MOST COMPLEX TO DATE, COMPRISING OF 45,000 INDIVIDUAL PIECES.

BAYER: THIS IS ONE OF THE SHAPES WE ARE USING ON THE SKINNY SKYSCRAPER, AND YOU CAN SEE ON ITS SHAPE THAT IT'S QUITE COMPLICATED, KEEPING IN MIND THAT WE HAVE TO RESPECT ALL THE DIMENSIONS TO THE MILLIMETER AND THAT WE HAVE TO MAKE 61 DIFFERENT SHAPES AND FOR THE WHOLE JOB, WE HAVE TO MAKE 45,000 PIECES JUST LIKE THIS.

NARRATOR: THE MACHINERY MAY HAVE IMPROVED, BUT THE PROCESS OF MANUFACTURING TERRA COTTA TILES HAS CHANGED LITTLE OVER THE DECADES.

NATURAL CLAY IS STILL REFINED, MOLDED, AND FIRED.

THE DIFFERENCE HERE IS THE SCALE OF PRODUCTION AND THE COLORS THAT CAN NOW BE PRODUCED.

TO ADD TEXTURE TO THE SKINNY SKYSCRAPER, THE TEAM HAS DEVELOPED 5 DIFFERENT SHADES FOR THE TOWER.

WHEN IN PLACE, THEY'LL HELP CREATE A PATTERN THAT TRACKS ACROSS THE FACADE AND WILL CHANGE AS THE SUN ROTATES AROUND THE BUILDING.

BAYER: THE IDEA WAS TO GET THE GLAZE MADE IN A COMPOSITION THAT, DURING THE PROCESS, DURING THE FIRING, IT WOULD FLOW DOWN IN THE VALLEYS OF THE TILE SHAPE TO GIVE A MORE INTENSE COLOR HERE AND THE WHOLE THING IN THE SUN REALLY MAKES IT WORKING OUT AS A VERY, VERY LIVELY SURFACE, AND IT STILL GIVES YOU THE TRADITIONAL FEELING OF A HANDMADE PIECE.

NARRATOR: WITH THE SHAPES AND COLORS NOW AGREED, MASS PRODUCTION OF THE TERRA COTTA TILES HAS BEGUN.

BAYER: ALL OF OUR KILNS WHERE ALL THE TILES ARE GETTING OFF FOR THE SKINNY SKYSCRAPER.

WHAT'S VERY IMPORTANT TO SAY IS THAT AFTER THE EXITING OF THE KILN, EACH INDIVIDUAL PRODUCT WILL BE QUALITY-CHECKED.

TO WAIT FOR THIS ONE DAY WHERE THE FIRST MASS PRODUCTION IS COMING OUT OF THE KILN, AND IT'S--EVEN AFTER 20 YEARS WITH THE COMPANY, STILL AN EXCITING MOMENT TO SEE HOW THE PRODUCT IS REALLY HAPPENING.

NARRATOR: AS THE FIRST TERRA COTTA TILES ROLL OFF THE PRODUCTION LINE, THEY'RE READIED FOR THE 4,000-MILE JOURNEY TO NEW YORK AND THEIR NEW HOME ON THE SKINNIEST SKYSCRAPER IN THE WORLD.

BY NOVEMBER 2016, CONSTRUCTION OF THE SKINNY SKYSCRAPER IS UP TO THE 13TH FLOOR OF STEINWAY HALL.

ALREADY, THE SITE'S 230-FOOT-TALL TOWER CRANE HAS REACHED ITS UPPER LIMITS, SO, THIS MORNING, ITS BIG BROTHER IS ON ITS WAY.

THE ALL-NEW TOWER CRANE WILL ATTACH TO THE SIDE OF THE BUILDING AND RISE WITH CONSTRUCTION TO THE VERY TOP.

MASTERMINDING ITS COMPLEX ASSEMBLY IS PROJECT MANAGER PAT FEEHAN.

RIGHT UP IN FRONT OF THAT CAR, YOU SHOULD BE SENDING CARS INTO THIS LANE.

MAN: ALL RIGHT.

NARRATOR: AT ANY OTHER TIME IN THE YEAR, INSTALLING A NEW CRANE WOULDN'T BE A PROBLEM.

BUT THANKSGIVING IS LOOMING.

SO, PAT HAS JUST 24 HOURS TO GET THE CRANE IN POSITION.

FEEHAN: THIS WEEKEND IS THE BEGINNING OF THE HOLIDAY EMBARGO, SO, THE CITY'S GONNA SHUT DOWN FOR ALL CRANE OPERATIONS, LIKE ERECTING MOBILE CRANES, FOR TWO MONTHS, SO, WE'D BE IN A BAD SPOT.

NARRATOR: TODAY, PAT'S OPERATION NEEDS TO RUN LIKE CLOCKWORK.

ANY DELAY AND CONSTRUCTION WILL BE POSTPONED FOR WEEKS, AND THE LONG-TERM CONSEQUENCES COULD BE FINANCIALLY CRIPPLING.

FEEHAN: THE ONLY THING THAT COMES THROUGH HERE IS AN AMBULANCE OR A BUS.

MAN: YEAH.

NARRATOR: AT 6 A.M., THE FIRST SECTION OF THE NEW CRANE ARRIVES.

ON ANY OTHER CONSTRUCTION, IT WOULD BE ASSEMBLED ON SITE.

BUT HERE...THAT'S IMPOSSIBLE.

WITH BUILDINGS ON ALL SIDES OF THE PLOT, THERE'S ONLY ONE OPTION-- TO CONSTRUCT IT FROM THE STREET.

THE ASSEMBLY CRANE NEEDED TO BUILD THE TOWER CRANE CAN LIFT OVER 300 TONS.

IT'S CRUCIAL IT'S PARKED IN EXACTLY THE RIGHT SPOT.

IF NOT, ITS MASSIVE WEIGHT COULD SINK INTO THE ROAD, DAMAGING THE BASE OF THE SKINNY SKYSCRAPER.

THERE'S A LOT OF COORDINATION ABOUT EXACTLY WHERE THESE LEGS LAY OUT.

IT LOOKS KIND OF HAPHAZARD BUT THERE'S A TON OF CALCULATIONS AND THEY'RE GONNA GO IN TO LAND THESE LEGS EXACTLY WHERE THEY NEED TO BE.

SO, THE LEGS ARE ACTUALLY SITTING ON THE FOUNDATION OF OUR VAULT FOR OUR BUILDING THAT WE POURED, AND THAT'S PART OF THE WHOLE, YOU KNOW, CALCULATIONS IN WHERE THIS THING HAD TO LAND.

NARRATOR: BY 8 A.M., THE GIANT MOBILE CRANE IS SAFELY IN POSITION.

BUT TO ASSEMBLE ITS 230-FOOT BOOM, THE TEAM NEEDS YET ANOTHER CRANE.

WE HAVE THE CHERRY PICKER THAT'S GONNA HELP BUILD THAT UP, AND ONCE THIS IS ASSEMBLED, THEN WE CAN START GETTING READY TO PUT SECTIONS ONTO THE TOWER CRANE.

IT'S EXTREMELY DANGEROUS.

IF SOMETHING GOES WRONG, I MEAN, IT'S...

IT'S CATASTROPHIC.

NARRATOR: TO ENSURE NOTHING IS LEFT TO CHANCE, EVERY MOVE HAS BEEN CAREFULLY PLANNED AND THEN PRE-APPROVED BY NEW YORK CITY DEPARTMENT OF BUILDINGS.

IT'S NOW THE RESPONSIBILITY OF THEIR SENIOR INSPECTOR TO ENSURE EVERYTHING IS CARRIED OUT TO THE LETTER.

AND HE'S A TOUGH MAN TO PLEASE.

MAN: THE WHOLE IDEA OF THIS IS PROTECTION OF THE PUBLIC, SO, WE HAVE TO PROTECT THOUSANDS OF PEOPLE HERE EVERY DAY, SO, THAT CRANE HAS TO BE SET UP PROPERLY AND IT HAS TO BE USED PROPERLY AND SAFELY.

IF NOT, THEN WE WILL SHUT IT DOWN.

WE'LL TELL THEM TO GO HOME TODAY.

NARRATOR: AS THE INSPECTOR CHECKS THE PAPERWORK, HE SPOTS A PROBLEM.

I GET WHAT YOU'RE SAYING.

NARRATOR: A CRUCIAL DOCUMENT IS MISSING, AND UNTIL IT'S FOUND, THE BUILD IS ON HOLD... THAT MEANS THAT WE CAN'T PUT THE CRANE UP.

NARRATOR: AND PRECIOUS TIME IS BEING LOST.

HE WAS SO QUICK TO SHUT THIS WHOLE [BEEP] JOB DOWN.

JUST LIKE THAT.

JUST LIKE THAT.

IF YOU HAVE A CODE TO FOLLOW, IF THEY'RE VIOLATING THE CODE, YOU'RE GONNA ISSUE THEM A VIOLATION, YOU GET A STOP WORK ORDER AND HAVE A NICE DAY.

PEOPLE CAN GET INJURED.

WELL, THAT'S WHAT WE WANT TO MAKE SURE DOES NOT HAPPEN.

NARRATOR: AFTER 50 FRANTIC MINUTES OF SEARCHING, PAT'S TEAM HAS A BREAKTHROUGH.

WHAT IS THAT DATE RIGHT THERE?

28, RIGHT?

9/28.

OK, THIS-- THIS RIGHT HERE IS THE REVISED THIRD PARTY THAT WAS IN THE DEPARTMENT.

I'M GONNA GO UPSTAIRS AND START PRINTING THIS STUFF RIGHT NOW.

SO, YOU CAN BRING IT DOWN HERE.

I'LL PRINT IT OUT.

NARRATOR: WITH THE PAPERWORK LOCATED THE INSPECTOR IS HAPPY.

MEYER: AND THAT'S BEEN APPROVED BY OUR OFFICE.

WE'RE GOOD.

YOU GOT IT.

THANK YOU.

NARRATOR: BUT NOW THE CLOCK'S TICKING.

FEEHAN: WE WERE IN JEOPARDY OF NOT BEING ABLE TO DO THIS.

I MEAN, THIS IS WEEKS OF PLANNING AND MULTIPLE MEETINGS AND COORDINATION.

IT'S FRUSTRATING, BUT WHEN I PRINTED THE EMAILS FOR THE INSPECTOR THAT WAS ON SITE SO HE COULD CONFIRM THAT HE HAD EVERYTHING, AND NOW WE HAVE ALL THAT, SO, NOW WE'RE GOOD TO GO.

[HORN BLOWS] NARRATOR: FOR THE NEXT TWO HOURS, THE TEAM RACE TO GET THE 72-TON ASSEMBLY CRANE BUILT.

BY 1 P.M., IT'S IN POSITION.

WORK CAN FINALLY BEGIN ON THE CONSTRUCTION OF THE ALL-NEW TOWER CRANE.

BUT NOW THERE'S ANOTHER PROBLEM.

FEEHAN: WE'RE UP AGAINST SOME WEATHER THAT'S COMING IN TONIGHT INTO TOMORROW, SO, WE JUST GOTTA GET IT DONE.

YOU KNOW, IT LOOKS LIKE WE'RE IN A GOOD SPOT RIGHT NOW, BUT A TIME CRUNCH, SO, IT'S IMPERATIVE THAT IT GETS DONE TODAY.

THERE IS NO NOT GETTING IT DONE.

SO, JUST POWER THROUGH AND GET IT DONE TODAY.

NARRATOR: AS DARKNESS DESCENDS, THE TEMPERATURE IN NEW YORK PLUMMETS.

BUT WITH ONE IMMOVABLE DEADLINE TO BEAT, THE TEAM HAS NO CHOICE BUT TO PLOW ON.

IT'S GONNA BE ONE LONG NIGHT.

8 A.M. ON THE SUNDAY OF THANKSGIVING WEEKEND.

THE TEAM HAVE WORKED AROUND THE CLOCK, AND HIGH ABOVE WEST 57TH STREET, THERE'S A NEW CRANE IN TOWN.

PAT AND HIS CREW HAVE BEATEN THEIR THANKSGIVING DEADLINE.

IT'S EXCITING 'CAUSE THIS IS, YOU KNOW, THIS IS A BIG STEP FOR US.

IT'S A MILESTONE ABOUT BRINGING US TO THE NEXT STAGE OF THE BUILDING.

THIS IS THE CRANE THAT'S GONNA BE WITH US TILL THE END NOW.

NARRATOR: WITH THE CRANE IN POSITION, THE SKY IS NOW THE LIMIT FOR THE SKINNY SKYSCRAPER.

IT'S FEBRUARY 2017.

3 YEARS AFTER WORK BEGAN AND THE WORLD'S SKINNIEST SKYSCRAPER IS FINALLY IN CLEAR AIR, HAVING RISEN ABOVE THE 16-STORY STEINWAY HALL.

NEW YORK'S NEWEST SUPER-TALL IS NOW OVER 1/5 OF THE WAY TOWARDS ITS FINAL 82-STORY HEIGHT.

I THINK BACK TO THOSE FIRST DAYS WHEN WE WERE DRAWING AND EVERY SINGLE DAY, I CAN'T BELIEVE IT'S GETTING BUILT.

THAT'S WHY I'M THRILLED EVERY DAY.

THAT'S WHY I CRANE MY NECK TO LOOK FOR IT.

IS IT REALLY TALLER?

NARRATOR: WITH THE EXTERIOR BUILD NOW RUNNING SMOOTHLY, PREPARATION FOR THE INTERIOR DESIGN AND CONSTRUCTION CAN BEGIN.

IN THIS HIGHLY EXCLUSIVE MARKET, EVEN THE SMALLEST OF FIXTURES AND FITTINGS ARE BEING DESIGNED WITH THE FUTURE MILLIONAIRE OWNERS IN MIND.

MAN: THIS BUILDING GOING UP, 111, ON WEST 57TH STREET, IS TRULY THE ONLY REAL LUXURY BUILDING.

NARRATOR: AND MARTIN GRUBMAN WOULD KNOW.

THE DEVELOPERS HAVE COMMISSIONED HIM TO PROVIDE DOZENS OF TOWEL BARS, HUNDREDS OF FAUCETS, AND THOUSANDS OF DOOR HANDLES FOR THE SKYSCRAPER.

BUT THIS IS NO ORDINARY HARDWARE FACTORY.

FOR OVER 160 YEARS, SINCE BEFORE SKYSCRAPERS EVEN EXISTED, P.E.

GUERIN HAS BEEN PRODUCING SOME OF THE BEST AND MOST EXPENSIVE BRASS HARDWARE MONEY CAN BUY.

BUT THE COMMISSION FOR THE SKINNY SKYSCRAPER IS THE LARGEST OF ITS KIND IN THE COMPANY'S LONG HISTORY.

GRUBMAN: ALL OF THE PRODUCT THAT WE NEED TO MAKE FOR 111 IS GOING TO TAKE ABOUT TWO YEARS.

I MEAN, THE THINGS ARE IN A SCALE THAT'S JUST MIND-BOGGLING.

NARRATOR: IN THIS ARTISAN BUSINESS, THERE ARE NO SHORTCUTS.

EVERY SINGLE BRASS ITEM HAS TO BE HANDMADE, PRODUCED BY A TEAM OF JUST 60 SKILLED CRAFTSMEN.

TODAY, THE TEAM IS PRODUCING THE LATEST BATCH OF DOOR HANDLES FOR THE SKYSCRAPER, SHAPED LIKE THE BUILDING ITSELF.

EACH ONE HAS ITS OWN ONE-OFF MOLD, WHICH IS FILLED WITH MOLTEN BRASS HEATED UP TO 2,000 DEGREES.

THIS PROCESS HASN'T CHANGED MUCH AT ALL.

THE BIGGEST IMPROVEMENT WE MADE WAS IN 1962, WE WENT FROM COKE-FIRED, WHICH IS COAL, TO GAS-FIRED.

THAT'S PROBABLY THE ONLY REAL IMPROVEMENT THAT'S BEEN DONE.

A REAL CHANGE.

RIGHT NOW, HE'S TESTING THE TEMPERATURE AND IT'S PERFECT.

1,967 DEGREES.

NARRATOR: ONCE THE BRASS HAS BEEN POURED, IT'S LEFT IN THE MOLD FOR 15 MINUTES.

IT'S THEN REMOVED, COOLED, AND PASSED TO THE NEXT TEAM FOR MACHINING AND FILING.

YOU CAN SEE HOW PAINSTAKING IT IS JUST BY WATCHING HOW LONG HE HAS TO DO THIS.

HE'LL SPEND HOURS JUST FILING THIS PIECE OF MATERIAL.

NARRATOR: JUST ONE DOOR HANDLE TAKES TWO DAYS TO PRODUCE BECAUSE WHEN YOU'RE PAYING FOR THIS TYPE OF QUALITY, NOTHING BUT PERFECTION WILL DO.

[MACHINE WHIRRING] THIS MAY BE THE FIRST SKYSCRAPER THE TEAM HAS BEEN SO INVOLVED WITH, BUT THEIR COMPANY IS NO STRANGER TO THE SITE OR STEINWAY HALL.

FOR DECADES, THE BRASS COMPONENTS FOR STEINWAY PIANOS WERE MADE RIGHT HERE.

THE TEAM NOW HAS JUST 9 MONTHS TO COMPLETE THEIR HISTORIC ORDER AND STAMP THEIR MARK ON A BUILDING THEY BELIEVE WILL BE WITHOUT EQUAL.

IT IS SO UNUSUAL FOR A DEVELOPER TO DO--TO WANT TO DO SOMETHING BETTER.

TYPICALLY, DEVELOPERS WANT TO DO SOMETHING CHEAPER AND FASTER.

SO, THE IDEA THAT THEY ACTUALLY WANT TO TAKE THE TIME AND WAIT FOR US TO MAKE THIS PRODUCT BY HAND AND PUT IT INTO THIS BUILDING IS JUST--IT'S BEYOND MY IMAGINATION.

NARRATOR: JUNE 2017.

HAVING BEEN COVERED WITH CONSTRUCTION NETTING FOR NEARLY 3 YEARS, THE NEWLY RESTORED STEINWAY HALL IS UNVEILED FOR THE FIRST TIME.

THE 1920S LIMESTONE FACADE HAS BEEN SANDBLASTED CLEAN, AND THE GOLD DETAILING RETURNED TO ITS FORMER GLORY.

BEHIND THE REVIVED LANDMARK BUILDING, THE SKINNY SKYSCRAPER IS NOW APPROACHING THE 20TH FLOOR.

AS THE TOWER STEADILY RISES, THE FIRST TERRA COTTA TILES HAVE ALREADY BEEN INSTALLED ON THE SIDE OF THE BUILDING.

BUT THESE TILES AREN'T JUST DECORATIVE.

THEIR CURVES WILL HELP REDUCE THE WIND SWAY AT THE TOP OF THE TOWER.

BUT EVEN WITH THE TILES, THE 3 OPEN WIND FLOORS, AND THE ROCK ANCHORS, IT'S STILL NOT ENOUGH TO STOP THE SKINNY TOWER FROM SWAYING COMPLETELY.

BACK IN CANADA, THE WIND SPECIALISTS HAVE BEEN TASKED WITH COMING UP WITH A SOLUTION.

MAN: IF YOU FAILED TO TAKE INTO CONSIDERATION HOW MUCH THE TOP OF THE BUILDING WAS GONNA MOVE, YOU COULD WIND UP CREATING A STRUCTURE THAT, ONCE SAMPLED, NOBODY WOULD WANT TO STAY IN.

NARRATOR: THE ANSWER IS TO COUNTERACT THE SWAY.

THIS REQUIRES THE FITTING OF A MASS DAMPER, OR PENDULUM.

BUT HAVING ALREADY LOST 3 FLOORS AS WIND CHANNELS, THE CHALLENGE NOW IS TO DESIGN A MASS DAMPER THAT DOESN'T SACRIFICE ANY MORE FLOOR SPACE.

HASKETT: THE DAMPER GENERALLY HAS TO GO ON THE TOP OF THE BUILDING.

THAT'S WHERE IT DOES THE BEST WORK.

BY ENHANCING THAT DAMPING CAPACITY, WE'RE ABLE TO ALLOW THE ARCHITECTS AND ENGINEERS TO MAKE STRUCTURES THAT REALLY OTHERWISE PROBABLY AREN'T SO HABITABLE.

NARRATOR: TO COUNTERACT THE SWAY OF THE 1,400-FOOT TOWER, TREVOR AND HIS TEAM HAVE COME UP WITH AN INGENIOUSLY COMPACT SOLUTION.

BY COMBINING TWO INDEPENDENT WEIGHTS, TOGETHER WEIGHING IN AT 800 TONS, THE EQUIVALENT OF 3 STATUES OF LIBERTY, THEY'VE DESIGNED THE WORLD'S HEAVIEST MASS DAMPER.

IT WILL FIT AT THE VERY TOP OF THE SKYSCRAPER, WHERE THE BUILDING IS AT ITS NARROWEST, SO IT WON'T CONSUME SELLABLE SPACE.

THIS, COMBINED WITH THE OTHER MEASURES, SHOULD FINALLY ENSURE ANY QUEASINESS IS STAMPED OUT FOR GOOD.

NOVEMBER 2017.

THE SKINNY SKYSCRAPER IS NOW UP TO THE 30TH FLOOR, AND THE AERODYNAMIC TERRA COTTA TILES NOW DECORATE LARGE SECTIONS OF THE TOWER.

THE BUILDING IS NOW VISIBLE FROM CENTRAL PARK.

CONSTRUCTION HAS SURPASSED 500 FEET.

WHEN COMPLETE, IT WILL BE ALMOST 3 TIMES HIGHER.

BUT THE SKYSCRAPER'S SMALL FOOTPRINT IS ONCE AGAIN CREATING ANOTHER UNIQUE CHALLENGE.

PASQUARELLI: WHEN WE WERE WORKING ON THE PROJECT, WE REALIZED THAT, YOU KNOW, WE HAD A LIMITED FLOOR PLATE IN THIS TOWER THAT WE COULD BUILD AND, YOU KNOW, WE KNEW THAT THE APARTMENTS NEEDED BOTH THE PASSENGER ELEVATORS AND THE SERVICE ELEVATORS, BUT PUTTING 4 ELEVATOR SHAFTS ON THE FLOOR PLATE EATS UP A TREMENDOUS AMOUNT OF THE SPACE OF THE APARTMENT.

NARRATOR: POTENTIAL OWNERS SPENDING UP TO $57 MILLION ON A HIGH-END, HIGH-SPEC APARTMENT WON'T BE IMPRESSED BY HAVING TO USE THE STAIRS.

SO, THE DESIGN TEAM TURNED TO THE COMPANY WHO PIONEERED THE VERY FIRST ELEVATOR TO SOLVE THEIR TRANSPORTATION PROBLEM.

MAN: SO, HERE WE ARE.

WE'RE TALKING ABOUT 111 WEST 57TH STREET, WHICH IS A VERY UNIQUE BUILDING.

IT'S VERY TALL, VERY SKINNY.

NARRATOR: IN 1854, COMPANY FOUNDER ELIJAH OTIS UNVEILED HIS ELEVATOR BRAKING SYSTEM AT THE WORLD FAIR IN NEW YORK.

IT WAS AN INVENTION THAT MADE HIGH-RISE BUILDINGS PRACTICAL FOR THE FIRST TIME, AND THE SKYSCRAPER WAS BORN.

ELIJAH'S COMPANY WOULD GO ON TO MAKE ELEVATORS FOR THE EMPIRE STATE BUILDING, THE EIFFEL TOWER, AND MORE RECENTLY, THE BURJ KHALIFA, THE WORLD'S TALLEST BUILDING.

BUT THE SKINNY SKYSCRAPER'S ELEVATORS DON'T JUST NEED TO REACH EXTREME HEIGHTS.

THEY NEED TO TAKE UP AS LITTLE SPACE AS POSSIBLE.

MAN: WELL, AT FIRST, FOR ME, I THOUGHT IT'S A TWO-ELEVATOR JOB IN A TOWER AND IT'S, YOU KNOW, PRETTY SIMPLE, BUT WHEN YOU START GETTING INTO IT, THERE'S A LOT OF REQUIREMENTS THAT REALLY MAKE IT VERY SPECIAL, HAS SOME UNIQUE CHALLENGES TO IT.

NARRATOR: TRADITIONALLY, RESIDENTIAL SKYSCRAPERS CONTAIN MULTIPLE ELEVATOR SHAFTS, BUT THE SKINNY SKYSCRAPER HAS ROOM FOR JUST TWO.

TO ENSURE THE RESIDENT MILLIONAIRES NEVER HAVE TO WAIT LONGER THAN 5 MINUTES FOR AN ELEVATOR, BOTH SHAFTS MUST BE USED FOR PASSENGER CARS.

THAT LEAVES NO ROOM FOR A SERVICE CAR, THE LIFELINE OF ANY SKYSCRAPER.

BUT BOB HAS A CUNNING SOLUTION.

KOLESZARIK: BECAUSE THERE'S SUCH A SMALL FOOTPRINT, THERE'S NO ROOM TO PUT A SERVICE ELEVATOR, SO, THE DESIGN SOLUTION WOULD BE TO DO A DOUBLE-DECK ELEVATOR.

NARRATOR: WHILE ONE ELEVATOR SHAFT WILL CONTAIN A SINGLE HIGH-END PASSENGER CAR, THE SECOND SHAFT WILL CONTAIN A DOUBLE-DECK CAB-- A PASSENGER COMPARTMENT ON TOP OF A SERVICE CAR BELOW.

AND THE RESIDENTS WILL BE DELIVERED DIRECTLY TO THEIR FLOOR, ELIMINATING THE NEED FOR LOBBY SPACE.

THAT'S VIP SERVICE.

SEEMS PRETTY STANDARD FOR NEW YORK.

HA HA!

NARRATOR: AS BOB AND HIS TEAM COMMENCE PRODUCTION OF THEIR DESIGN...

IN MANHATTAN, THE SKINNY SKYSCRAPER HAS REACHED 700 FEET, PASSING THE HALFWAY STAGE OF THE BUILD.

THERE'S NOW JUST ONE PROBLEM.

THE TOWER WAS DUE TO BE FINISHED TWO MONTHS FROM NOW AND THERE ARE STILL NEARLY 40 FLOORS LEFT TO BUILD.

WORK ON THE INTERIORS HAS YET TO EVEN BEGIN.

♪ JUNE 2018.

THE SKINNY SKYSCRAPER WAS SCHEDULED TO BE MOVE-IN READY, BUT THE BUILDING IS STILL FAR FROM FINISHED.

THERE ARE OVER 30 OF THE 82 FLOORS TO GO.

THE COMPLEXITY OF THE BUILD AND FINANCIAL COMPLICATIONS HAVE NOW THROWN THE SCHEDULE OUT THE WINDOW, AND THE END DATE HAS BEEN MOVED TO 2020.

BUT BUILDING THE WORLD'S SKINNIEST SKYSCRAPER WAS NEVER GONNA BE EASY.

PASQUARELLI: WE'VE JUST PASSED ABOUT 900 FEET ON THE TOWER HEIGHT.

IT'S A VERY DIFFICULT ONE TO CONSTRUCT.

BUT NOW WE'RE FEELING INCREDIBLY CONFIDENT.

AS THE FACADE GOES ON, WE JUST FEEL INCREDIBLY EXCITED, 'CAUSE IT'S AS GOOD, IF NOT BETTER, THAN OUR HIGHEST HOPES AND ASPIRATIONS.

NARRATOR: HAVING BATTLED THE HARDEST BEDROCK IN MANHATTAN, INTERTWINED OLD WITH NEW, AND PIONEERED 21ST-CENTURY BUILDING SOLUTIONS, THE TOUGHEST PART OF THE BUILD IS NOW A LONG WAY BELOW.

PASQUARELLI: WATCHING THE BUILDING GO UP IS ONE OF THE MOST EXHILARATING FEELINGS YOU COULD EVER IMAGINE, AND EACH LEVEL THAT IT GOES UP AND MORE AND MORE THAT YOU'RE STARTING TO SEE THE FORM AND THE FACADE IS GOING UP, YOU'RE REALLY GETTING TO SEE WHAT YOU HAD HOPED IT WOULD BE, AND WHEN IT EVEN EXCEEDS YOUR GREATEST HOPES, THAT'S A PRETTY GOOD FEELING.

NARRATOR: WITH THE FIRST OF 12 ARCHITECTURAL SETBACKS IN PLACE, THE SKINNY SKYSCRAPER WILL NOW TAPER TO THE TOP AS IT CLIMBS EVER HIGHER ABOVE MIDTOWN MANHATTAN.

KOSTER: I THINK IT'S REESTABLISHING WHAT NEW YORK LOVED ABOUT ITS ARCHITECTURE SO LONG AGO AND EMBRACING WHAT A TALL BUILDING CAN BE.

BAYER: HAVING SEEN THE BUILDING GOING UP, I DON'T THINK THERE'S ANOTHER SKYSCRAPER IN THE WORLD WHICH YOU CAN COMPARE WITH IT.

NARRATOR: THE SKINNY SKYSCRAPER IS ON COURSE TO BECOME A SHOW-STOPPER WITHIN THE MOST ICONIC SKYLINE ON EARTH.

GREGG PASQUARELLI'S CHILDHOOD DREAM HAS BEEN REALIZED.

PASQUARELLI: I GREW UP HERE IN NEW YORK, AND TO THINK THAT WE'VE BEEN ABLE TO REDEFINE WHAT A SKYSCRAPER WOULD BE, BUILDING THE MOST SLENDER SKYSCRAPER IN THE WORLD ON THE NEW YORK SKYLINE, IT'S JUST REALLY SHOWING WHAT THE POSSIBILITIES ARE FOR THE FUTURE.