0:00:11 > 0:00:13The submarine's huge. It's 100 metres long.
0:00:13 > 0:00:15It's three decks deep.
0:00:15 > 0:00:18There is no inch of the submarine that's similar to another inch of it.
0:00:18 > 0:00:22I would definitely put it in the same league as the Space Shuttle
0:00:22 > 0:00:23or projects of that size.
0:00:26 > 0:00:30To my mind, this is a 7,000-tonne Swiss watch.
0:00:30 > 0:00:33There's an extraordinary amount of expertise
0:00:33 > 0:00:35in putting one of these submarines together.
0:00:35 > 0:00:38There are stages when it's like blacksmithing
0:00:38 > 0:00:40and there are stages when it's like brain surgery.
0:00:46 > 0:00:50The team what I've got have been working together for over 20-odd years.
0:00:50 > 0:00:53I mean, we're used to a lot heavier. This is a baby.
0:00:56 > 0:01:01I'll be fully qualified in September 2010, which is really daunting -
0:01:01 > 0:01:04being able to say, "I will be a qualified electrician."
0:01:05 > 0:01:08I'm in charge of purchasing submarines
0:01:08 > 0:01:11for the Ministry of Defence and it's my job to make sure that
0:01:11 > 0:01:15the programmes that we're hearing from the company are sensible
0:01:15 > 0:01:18and real and we're getting value for money out of them.
0:01:22 > 0:01:24This is number-one sea gate,
0:01:24 > 0:01:28and at the moment, she's laying down in the recess and we can't shut it,
0:01:28 > 0:01:30and make this area non-tidal.
0:01:32 > 0:01:35It's obviously quite a serious thing when a 380-tonne gate
0:01:35 > 0:01:37has collapsed on the bottom.
0:01:37 > 0:01:41It's a big, big engineering challenge.
0:01:41 > 0:01:46Without that gate in place, this submarine will not leave Barrow.
0:01:46 > 0:01:49This is a key point for the Royal Navy, bringing Astute out.
0:01:49 > 0:01:55If I get that wrong, I'm certainly aware of the amount of scrutiny that will be coming down on me.
0:01:55 > 0:01:57Anthony, my son, he said, "What do you do, Daddy?"
0:01:57 > 0:02:00He said, "I build submarines for the Queen."
0:02:12 > 0:02:17It's a wet and windy weekend in the middle of November.
0:02:17 > 0:02:20And the first new British submarine to be built for ten years
0:02:20 > 0:02:23is now preparing to sail out into the open sea
0:02:23 > 0:02:25for the very first time.
0:02:27 > 0:02:29- Is my cap badge in the middle?- Yes. You're perfect.
0:02:29 > 0:02:32Good. Because often it's round there.
0:02:32 > 0:02:3414 years in the making
0:02:34 > 0:02:36and costing over £1 billion,
0:02:36 > 0:02:40she is one of the most technologically advanced machines in the world.
0:02:40 > 0:02:42She's a world class submarine,
0:02:42 > 0:02:46in her sense of technology underwater and above water,
0:02:46 > 0:02:48the weapons she can carry to sea
0:02:48 > 0:02:51that attack not only ships, but the land targets.
0:02:51 > 0:02:53She's an awesome vessel.
0:02:57 > 0:02:58Impressive as she is,
0:02:58 > 0:03:03her final exit into the open sea is not going to be an easy one.
0:03:06 > 0:03:09Much of Britain has experienced the worst storms of the year,
0:03:09 > 0:03:11with strong winds and heavy rain
0:03:11 > 0:03:13causing flooding and damage across the country.
0:03:17 > 0:03:21We have very strict criteria for making sure we have a safe exit.
0:03:21 > 0:03:24And the rain only affects the visibility on the day.
0:03:24 > 0:03:26It's the wind that matters.
0:03:27 > 0:03:28This is the story of
0:03:28 > 0:03:33how one of the world's most complicated machines is built.
0:03:33 > 0:03:35And the people that build it.
0:03:57 > 0:04:00It's about five to seven and I'm going to work.
0:04:08 > 0:04:11I've been in the Navy almost 30 years now
0:04:11 > 0:04:15and I've spent probably literally about 15 years underwater in submarines.
0:04:26 > 0:04:29It's the start of a typical working day
0:04:29 > 0:04:32for the people who build Britain's nuclear submarines.
0:04:33 > 0:04:36There is a lot of people that I know that work in the yard.
0:04:36 > 0:04:40Obviously there's Ged, my husband. My sister-in-law works in there.
0:04:40 > 0:04:44My brother-in-law works in there. My brother works in there.
0:04:47 > 0:04:49I would say every family that I know,
0:04:49 > 0:04:52at least one or two people actually work in the yard.
0:04:52 > 0:04:56Barrow-in-Furness is a town of 62,000 people
0:04:56 > 0:04:59on the edge of the English Lake District.
0:04:59 > 0:05:02The town has an amazing history of building submarines,
0:05:02 > 0:05:05launching its first in 1887.
0:05:05 > 0:05:08It only takes me about ten minutes, if that, to get to work.
0:05:08 > 0:05:12And generations of the same families from all around the area
0:05:12 > 0:05:14still build them today.
0:05:14 > 0:05:15I'm just swiping on.
0:05:15 > 0:05:19This is electronic timekeeping to make sure we're in at the right time and not late.
0:05:41 > 0:05:46The capability of our submarines is something that we want to keep to ourselves,
0:05:46 > 0:05:51because if other countries, other organisations, know the capability of the units, which we operate,
0:05:51 > 0:05:53then they can develop ways of defeating that capability.
0:05:55 > 0:05:59So that's why we're very careful about who comes on this site
0:05:59 > 0:06:02and also what information we're allowed to give as well.
0:06:06 > 0:06:10The current owner of the shipyard is British defence company BAE Systems.
0:06:10 > 0:06:15The business employs over 35,000 people across the UK,
0:06:15 > 0:06:19with around 5,000 of them in Barrow alone.
0:06:19 > 0:06:23BAE Systems is not without its critics.
0:06:23 > 0:06:27But in this town, the company forms the very backbone of the local economy.
0:06:30 > 0:06:33We have extraordinary numbers of people working here,
0:06:33 > 0:06:36with all sorts of family relationships. And the business has
0:06:36 > 0:06:41a real family feel to it as well. We play a vital part in the community.
0:06:41 > 0:06:45A lot of salaries and money goes back into the community through our shipyard.
0:06:46 > 0:06:49Britain's need for submarines splits opinion.
0:06:49 > 0:06:51Some think they're critical for defence,
0:06:51 > 0:06:56others that they're a waste of taxpayers' money.
0:06:56 > 0:07:00But with a potential order book of seven Astute submarines,
0:07:00 > 0:07:04Barrow depends on them to prosper into the next decade and beyond.
0:07:05 > 0:07:09This is the only site in the UK where we design, build, test and commission
0:07:09 > 0:07:13nuclear submarines for the Royal Navy.
0:07:13 > 0:07:18Britain's current fleet of attack submarines are coming to the end of their working lives,
0:07:18 > 0:07:22and the Royal Navy are desperate to get their hands on this new class.
0:07:22 > 0:07:25One of the world's most technologically advanced machines,
0:07:25 > 0:07:29they pack weaponry, life support and all the sensitive equipment
0:07:29 > 0:07:31a submarine needs to operate -
0:07:31 > 0:07:35including a nuclear reactor that will power its engine for 25 years
0:07:35 > 0:07:37and never need refuelling.
0:07:37 > 0:07:41At almost £1 billion, this submarine doesn't come cheaply.
0:07:41 > 0:07:43Or quickly.
0:07:43 > 0:07:46The submarines take years to manufacture. But what we do have
0:07:46 > 0:07:50on-site here are four submarines in various stages of their build.
0:07:50 > 0:07:55The first one is afloat, outside the Devonshire Dock Hall.
0:07:55 > 0:07:59The second submarine is behind me. The third submarine is just about whole.
0:07:59 > 0:08:02We've got a few more units to weld together.
0:08:02 > 0:08:05And the fourth submarine is, at the moment,
0:08:05 > 0:08:08in a series of units being outfitted.
0:08:08 > 0:08:11So you can look around the site here and see from first rolling the steel
0:08:11 > 0:08:15to actually operating the systems and preparing to go to sea.
0:08:17 > 0:08:21Building four boats with a staggered production schedule,
0:08:21 > 0:08:24the range of skills needed on site is extraordinary.
0:08:24 > 0:08:27The people here are unique - in not only what they do,
0:08:27 > 0:08:28but how they do it.
0:08:30 > 0:08:33I'm just changing into my overalls.
0:08:33 > 0:08:39I have to wear them so you don't cut yourself or hurt yourself.
0:08:39 > 0:08:42But they're not very flattering, to say the least.
0:08:44 > 0:08:47I work on that boat. Boat two, Ambush.
0:08:47 > 0:08:50This one closer to us is boat three.
0:08:50 > 0:08:54We're going down there, to the toolbox talk.
0:08:55 > 0:08:57That's Nige, the team leader.
0:08:57 > 0:08:58Morning, Nige.
0:08:58 > 0:09:01Erin Browne will be trained in the electrical systems
0:09:01 > 0:09:05of the submarine and is one of only 300 electricians on the build.
0:09:05 > 0:09:10When she's qualified, she'll be part of a very elite and highly-skilled club.
0:09:10 > 0:09:14That was our toolbox talk. We have one every morning at half past seven,
0:09:14 > 0:09:17telling us any health and safety issues from the day before,
0:09:17 > 0:09:21any communications - basically keeping us in touch with what's going on around the yard.
0:09:21 > 0:09:24The whole site covers 169 acres,
0:09:24 > 0:09:27making it Britain's biggest shipyard.
0:09:33 > 0:09:35And as a hub of high technology,
0:09:35 > 0:09:39nuclear submarines aren't just built in Barrow - they're designed here, too.
0:09:39 > 0:09:43The submarine is designed to operate in a very hostile environment,
0:09:43 > 0:09:45which is under the sea, at pressure.
0:09:45 > 0:09:48It's a salty environment - it wants to corrode.
0:09:48 > 0:09:51At the same time, it has to keep its crew
0:09:51 > 0:09:53of 97 crew safe
0:09:53 > 0:09:56for about a three-month period without surfacing.
0:09:59 > 0:10:03So it has to make it on air, its own water. Carries its own food.
0:10:03 > 0:10:07It has to operate as a war-fighting machine as well.
0:10:08 > 0:10:12The submarine has to be able to withstand underwater strikes and explosions.
0:10:12 > 0:10:16And so computer simulations put the hull through extreme testing,
0:10:16 > 0:10:20to ensure it will keep its crew safe if attacked.
0:10:25 > 0:10:29With around 600 people involved in the design process alone,
0:10:29 > 0:10:33this is one of the largest concentrations of such expertise in the world.
0:10:42 > 0:10:45This is the most complex submarine we've ever built.
0:10:45 > 0:10:49It's got 250,000 miles' worth of cable onboard the boat.
0:10:49 > 0:10:51It's got something like about 25,000 valves.
0:10:51 > 0:10:54We have to produce more than 100,000 drawings,
0:10:54 > 0:10:59so all the drawings originate from our computer-aided model.
0:11:07 > 0:11:10It took four years to design the Astute,
0:11:10 > 0:11:13which will contain more than a million individual components.
0:11:13 > 0:11:15Designed on a computer,
0:11:15 > 0:11:18but built by hand.
0:11:27 > 0:11:30My job is steelwork team leader.
0:11:30 > 0:11:33Started off as a shipwright in 1982
0:11:33 > 0:11:34and worked my way through the business.
0:11:37 > 0:11:40I've been in this shop now for about 12 years.
0:11:44 > 0:11:47This is the place where all the submarines start out life.
0:11:47 > 0:11:50This is where the raw plates come in by road.
0:11:50 > 0:11:52The wagons back into the shop,
0:11:52 > 0:11:55the magnet crane removes them and puts them into the piles.
0:11:56 > 0:11:59Using a plasma cutting machine,
0:11:59 > 0:12:02each plate has carefully designed patterns burnt into them.
0:12:02 > 0:12:05When each plate comes off the burning machine,
0:12:05 > 0:12:08what we do, we leave a small stitch of metal,
0:12:08 > 0:12:12which stops all the individual pieces falling out on the floor.
0:12:13 > 0:12:17Peter, the burner, what he's doing now is cutting through all the little stitches
0:12:17 > 0:12:19so the piece parts will fall out.
0:12:19 > 0:12:24They all go where they need to be, to be built in the right time, just like a massive Airfix model.
0:12:30 > 0:12:32The steel that makes the hull
0:12:32 > 0:12:36is shaped and rolled until the massive sections are completed.
0:12:38 > 0:12:42Peel away the special coating and the pressure hull is simply a watertight tube,
0:12:43 > 0:12:46capped at both ends with tanks that fill with water,
0:12:46 > 0:12:47to help it dive and surface.
0:12:47 > 0:12:50And finally, there's a fin section on top.
0:12:50 > 0:12:53The hull is made of eight separate steel sections,
0:12:53 > 0:12:56each around 11 metres in diameter.
0:12:56 > 0:13:01The boat is 97 metres long and when finished, weighs 7,400 tonnes.
0:13:03 > 0:13:07The huge sections are made in a different part of the yard
0:13:07 > 0:13:10and when completed, need to be transported down a public road
0:13:10 > 0:13:13to the building where the vessel is actually put together.
0:13:23 > 0:13:26At 260 metres long,
0:13:26 > 0:13:2958 metres wide and 51 metres tall,
0:13:29 > 0:13:32this building is one of Britain's biggest sheds!
0:13:35 > 0:13:39This is the DDH, which stands for Devonshire Dock Hall.
0:13:39 > 0:13:43The submarines are built in here because it's where all the top-secret stuff is,
0:13:43 > 0:13:49where people can't see, so it's housed and it's hidden. It's where the magic happens, I suppose.
0:14:01 > 0:14:04The Astute is the first class of British submarine
0:14:04 > 0:14:06in which sections are worked on vertically.
0:14:06 > 0:14:09This allows easy access for the team,
0:14:09 > 0:14:12before the section is turned the right way up, or ship-wise.
0:14:15 > 0:14:18Right. What we've got is a unit like this.
0:14:18 > 0:14:22We'll lower it down until it's on its two turning shoes at the far end there.
0:14:22 > 0:14:26What we'll then do is rig Frank up to the shop crane up here.
0:14:26 > 0:14:31He'll start turning it over like this, so it's rolling on the two turning shoes.
0:14:49 > 0:14:52My job is just a second set of eyes, just to make sure
0:14:52 > 0:14:56that everything's running smoothly.
0:14:56 > 0:14:57I'm the appointed person. If anything goes wrong.
0:14:57 > 0:14:59It's me that gets it in the neck.
0:15:02 > 0:15:05We're at a critical stage now in this turn
0:15:05 > 0:15:09where we've transferred the weight of the unit onto the mobile crane.
0:15:09 > 0:15:12The mobile crane is holding the load.
0:15:12 > 0:15:14We're now going to derig the shop crane and
0:15:14 > 0:15:17rerig it onto these eyeplates on this lower side of the unit.
0:15:17 > 0:15:21It's a critical point now. If either of these two cranes fail...
0:15:21 > 0:15:25Well, I wouldn't like to be standing here. I'll put it that way.
0:15:34 > 0:15:39A submarine packs in three times more machinery and equipment than any surface ship.
0:15:39 > 0:15:43But most of the back of the boat is taken up with the nuclear reactor,
0:15:43 > 0:15:46the engine and all the different back-up systems.
0:15:51 > 0:15:54We're now in the diesel generator space.
0:15:54 > 0:15:58Should we lose a reactor at sea, then we would rely on these diesel engines to provide
0:15:58 > 0:16:03the electrical power for running the minimum of equipment that we need to live as human beings.
0:16:03 > 0:16:08If you really need them at sea, then it's a bad hair day and you've got some problems, yeah.
0:16:08 > 0:16:12For a submarine to operate effectively, it has to be virtually undetectable.
0:16:12 > 0:16:16To do this, machinery is isolated from shocks, noise and vibration.
0:16:16 > 0:16:22This mounting here is an example of how you decouple the noise or the vibration
0:16:22 > 0:16:27generated from the diesel engine here from a sensitive piece of equipment.
0:16:27 > 0:16:30You can see here that this allows this piece of equipment to move.
0:16:30 > 0:16:33We expect the Astute class to be one of the,
0:16:33 > 0:16:35if not THE, quietest submarine in the world.
0:16:35 > 0:16:39One of the reasons for that is the technology we employ on here
0:16:39 > 0:16:42to prevent the vibration being transmitted to the hull.
0:16:43 > 0:16:46MUSIC: "The Blue Danube"
0:16:54 > 0:16:59Today, boat three is taking shape as some of her biggest sections are moved into position.
0:16:59 > 0:17:02Submarines take on water to help them dive.
0:17:02 > 0:17:08And a lot of it comes into the streamlined 270 tonne forward end construction.
0:17:08 > 0:17:12This unit also houses the submarine's sonar equipment.
0:17:17 > 0:17:21Active sonar works by emitting a pulse of sound and then calculates
0:17:21 > 0:17:25the amount of time it takes to hit an object and bounce back, which determines the distance.
0:17:25 > 0:17:28But the Astute will normally use passive sonar,
0:17:28 > 0:17:32which simply listens to the sea to detect and identify objects.
0:17:32 > 0:17:36It's claimed this technology is sensitive enough to hear a boat
0:17:36 > 0:17:40leaving New York harbour from Southampton.
0:17:40 > 0:17:43The other end of the submarine is capped with the after-end construction.
0:17:43 > 0:17:49Weighing in at around 230 tonnes, this also takes on water when the submarine dives and
0:17:49 > 0:17:53houses the mechanisms that control the submarine's rudder and propeller shaft.
0:17:55 > 0:17:58My name is Derek Parker and I work for Production Services team.
0:17:58 > 0:18:02We're in charge of all major movements in the DDH.
0:18:02 > 0:18:05Do all the heavy lifting, do all the shipping and modules
0:18:05 > 0:18:07and moving of the units.
0:18:07 > 0:18:10We're setting up now ready to move the aft-end construction
0:18:10 > 0:18:12up to the after dome.
0:18:12 > 0:18:14There's four transfer cars.
0:18:14 > 0:18:19They can actually pick up to 250 tonne per car.
0:18:19 > 0:18:20We're moving 39 metres
0:18:20 > 0:18:23and it's a metre a minute it travels.
0:18:23 > 0:18:25Everything's away, so...
0:18:25 > 0:18:28we're ready for this. We're ready to go then, boys.
0:18:28 > 0:18:31Green button. Let's go. Thank you.
0:18:45 > 0:18:47The team what I've got have been working together
0:18:47 > 0:18:49for over 20-odd years,
0:18:49 > 0:18:52so they know the system inside out.
0:18:52 > 0:18:54I mean, we're used to a lot heavier.
0:18:54 > 0:18:56We're used to something like 600 tonne,
0:18:56 > 0:19:00putting it together against another unit. This is a baby.
0:19:00 > 0:19:01This is a little baby!
0:19:03 > 0:19:06As we get six foot off the unit, we have to put people inside.
0:19:06 > 0:19:11So we bring more people in cos we've got to watch as we go up towards the dome,
0:19:11 > 0:19:13so that we don't hit that unit.
0:19:31 > 0:19:34As you can see, we've only got three inches to go now.
0:19:34 > 0:19:38Now we're going to go on an inch button, where we can do it an inch at a time.
0:19:38 > 0:19:41Inch it up, Tony. That's right, mate.
0:19:43 > 0:19:44Just the last inch, now, boys.
0:19:47 > 0:19:49That's it. Thank you.
0:19:49 > 0:19:52We can't do anything more with the transfer system. That's as close as we can get it.
0:19:52 > 0:19:55And it's within half an inch.
0:19:55 > 0:19:56It's gone well.
0:20:05 > 0:20:08One of the biggest and most complicated areas of the submarine
0:20:08 > 0:20:11is the command deck - the nerve centre of the boat,
0:20:11 > 0:20:14built as a separate module in another part of the shipyard,
0:20:15 > 0:20:20The command deck module is 22 metres long and weighs 180 tonnes.
0:20:20 > 0:20:25It contains the navigational controls, sonar, communications and weapons systems.
0:20:25 > 0:20:28The captain's cabin is on the top deck, while the second deck
0:20:28 > 0:20:32is where food is prepared and the crew eat, sleep and relax.
0:20:32 > 0:20:34We put all the the combat system together here,
0:20:34 > 0:20:38make it talk to each other and then the boat gets fleeted from here
0:20:38 > 0:20:41down to the submarine, then set back in the submarine.
0:20:46 > 0:20:48This is called the sonar cab space.
0:20:48 > 0:20:51Various equipment in here - the processing for the sonar,
0:20:51 > 0:20:55for the networks, for the command systems.
0:20:55 > 0:20:57I'll show you the sound room.
0:20:57 > 0:20:59This is where the sonar sets up.
0:20:59 > 0:21:01This is all the command system.
0:21:01 > 0:21:04All the sonars and all the other equipment on board
0:21:04 > 0:21:08pass all their information across to these desks.
0:21:08 > 0:21:11OK, carrying on aft, this is the commanding officer's cabin.
0:21:11 > 0:21:15Again, at the moment, it's pretty bare.
0:21:15 > 0:21:18The captain is the only man onboard who has a cabin to himself.
0:21:18 > 0:21:20He's the sole occupant of this one.
0:21:22 > 0:21:26This is the lower deck of the CDM, which is mainly accommodation.
0:21:26 > 0:21:30There's 19 bunks in this space - quite cramped.
0:21:30 > 0:21:36But nothing different to what submariners are used to and have been used to for many years.
0:21:36 > 0:21:40When I was in the Navy, all we had was a bunk light.
0:21:40 > 0:21:44Nowadays, they have iPod chargers, they have all sorts.
0:21:46 > 0:21:49OK, coming to the after-end of the command deck now,
0:21:49 > 0:21:52we have both the junior eights' and the senior eights' messes.
0:21:52 > 0:21:56This is where they live when they're off watch as well.
0:21:56 > 0:21:59And the final compartment is the galley.
0:21:59 > 0:22:01Or the kitchen.
0:22:01 > 0:22:05It's got every possible modern convenience.
0:22:05 > 0:22:08Everything. I don't know - it's got more than my kitchen has!
0:22:10 > 0:22:12There's a little bit of finishing off still to do,
0:22:12 > 0:22:16but we're not far off completion, whereby this will then be transported
0:22:16 > 0:22:21down to the DDH and slotted into the submarine.
0:22:26 > 0:22:29Once the units are fully fitted out, they can be joined together.
0:22:31 > 0:22:35We're going right through this unit into the next unit, and we're going to go down the tank.
0:22:35 > 0:22:38A job for the welding team.
0:22:41 > 0:22:44There's always one squad on nights, one squad on days.
0:22:44 > 0:22:46We will be on the job until it's finished.
0:22:50 > 0:22:53It's hard work. I'm on my second T-shirt now. I'm sweating.
0:22:53 > 0:22:57I'm tired. I'm going to be here till about seven o'clock tonight. So...
0:23:01 > 0:23:05We all have a section each. Start at the same time, finish at the same time, more or less.
0:23:05 > 0:23:09Hopefully, the results are all the same - the welding's good.
0:23:15 > 0:23:19Compared to some of the spaces on this submarine, this space is big.
0:23:22 > 0:23:23This is my job down here.
0:23:23 > 0:23:27I've got to crawl down this gap on this ladder to get down.
0:23:27 > 0:23:31The job will take over two kilometres of welding to complete,
0:23:31 > 0:23:33so the team will have to work in unison,
0:23:33 > 0:23:37with accuracy being key to ensure the units are in perfect alignment.
0:23:37 > 0:23:39Other side of that bulk head is the nuclear reactor.
0:23:39 > 0:23:44To the right, the command deck module goes in this side.
0:23:44 > 0:23:48This is my gun. Press the trigger and the gas comes out first.
0:23:48 > 0:23:49Then you let go of the trigger.
0:23:49 > 0:23:53The wire obviously feeds out with the power going through it.
0:23:53 > 0:23:56If you get too hot or get too dry mouth or lose too much fluid, you've got to come out.
0:24:05 > 0:24:08Heat-wise, it's the same everywhere.
0:24:08 > 0:24:11It's extremely hot wherever you are, as you can see.
0:24:11 > 0:24:14It is hot. It's hard work. It is a hard job to do.
0:24:14 > 0:24:17It will take eight welders working day and night shifts
0:24:17 > 0:24:21three weeks to join just two parts of the submarine together.
0:24:21 > 0:24:26And the tanks they work in can reach temperatures of up to 130 degrees.
0:24:28 > 0:24:31On a job like this, we'll be doing miles of welding.
0:24:31 > 0:24:32Absolutely.
0:24:32 > 0:24:37We used coils of wire and I think they hold about about 10lb of wire.
0:24:37 > 0:24:40We can put one or two of them in in a shift, easy.
0:24:40 > 0:24:43So...there's a lot of welding involved.
0:24:43 > 0:24:46I take pride in my work. I think a lot of the welders do.
0:24:46 > 0:24:49It's a bit of a challenge now and again, so yeah.
0:24:49 > 0:24:51Bit of a challenge with each other as well.
0:24:51 > 0:24:54When you're welding, it's got to be right.
0:24:54 > 0:24:56We have a bit of a laugh over it -
0:24:56 > 0:25:00bit of a dig at each other - so you take pride in your work that way.
0:25:00 > 0:25:03Ged's worked in the yard
0:25:03 > 0:25:05for about 25 years now.
0:25:05 > 0:25:08He left school when he was 16 and went straight into the yard.
0:25:08 > 0:25:10Left in the June and went in the September.
0:25:10 > 0:25:16I like it because I think it's permanent, it's stable.
0:25:16 > 0:25:18You know, he's got a good job there
0:25:18 > 0:25:20and he's home from work within five minutes.
0:25:20 > 0:25:24A welder's a very, very manual job. Very dirty.
0:25:24 > 0:25:29And he has to get into some sort of tight spots that I certainly couldn't get into, so...
0:25:32 > 0:25:38Once the welding is finished inside, the team move to the outside of the hull to complete the job.
0:25:43 > 0:25:45It's quite an important job.
0:25:45 > 0:25:48If anything goes wrong with the job,
0:25:48 > 0:25:52it goes on my record. I did my first one of these age 18.
0:25:52 > 0:25:54I think I'm the youngest one to do one.
0:25:56 > 0:25:58Quite proud of it as well, really.
0:26:01 > 0:26:03This is finished now. They'll crack-detect it.
0:26:03 > 0:26:06Then it'll get ultrasonic tested,
0:26:06 > 0:26:08which is just like a baby scan, really.
0:26:08 > 0:26:10You put jelly on it, put a probe over it.
0:26:10 > 0:26:13Just to make sure there's no muck or defects in the metal.
0:26:13 > 0:26:17Then they'll X-ray it just to further check it again. Just to make sure.
0:26:17 > 0:26:20There's lives at risk, so it's got to be right.
0:26:22 > 0:26:24Where there is a join,
0:26:24 > 0:26:26there is usually a weakness.
0:26:26 > 0:26:28But in the case of the Astute,
0:26:28 > 0:26:32the metal used by the welders is actually stronger than the hull.
0:26:32 > 0:26:37This innovative work is done on-site by a team of scientists and engineers.
0:26:40 > 0:26:41In the mechanical test area,
0:26:41 > 0:26:45there are various pieces of equipment and techniques
0:26:45 > 0:26:49which allow us to characterise the way materials behave,
0:26:49 > 0:26:52such as tensile testing, which we use to pull material apart.
0:26:54 > 0:26:57Or impact testing.
0:26:57 > 0:27:00When two sections of the submarine are joined together,
0:27:00 > 0:27:04we will have specified the materials that have been joined together.
0:27:04 > 0:27:09We will have developed the process which joins the material together.
0:27:09 > 0:27:15And we will have assessed the suitability of the material that goes into joining the two pieces together.
0:27:22 > 0:27:24Boat two is ready to be out-fitted.
0:27:24 > 0:27:28The vessel will eventually contain over one million components,
0:27:28 > 0:27:34which includes 23,000 pipes and over 100 kilometres of electrical cabling.
0:27:34 > 0:27:36Just going to go into the workshop now -
0:27:36 > 0:27:39go see Carl and see what the plan of action is for today.
0:27:39 > 0:27:44With a maximum of 290 people allowed onboard boat two at any one time,
0:27:44 > 0:27:47the different teams need to work together.
0:27:47 > 0:27:49They will literally build her by hand.
0:27:49 > 0:27:52The job that we're doing today is going to be in the captain's cabin,
0:27:52 > 0:27:55so it's quite a small compartment.
0:27:58 > 0:28:02Just been to the PAM cabin to get our PAMs - personal air monitors.
0:28:02 > 0:28:06We need them for gases or there's a gas leak, such as argon.
0:28:06 > 0:28:11Argon's really dangerous. They say two lungfuls and it kills you straightaway. So, nasty!
0:28:11 > 0:28:16Before we go onboard, the last thing we've got to do is swipe on with our passes.
0:28:16 > 0:28:19That's just so they know how many people are onboard,
0:28:19 > 0:28:23so that if there's a fire, they know how many people to get off-board. Things like that.
0:28:28 > 0:28:33Erin is one of 500 apprentices and graduates working in the shipyard.
0:28:33 > 0:28:36Apprentice schemes all over Britain are now being reintroduced,
0:28:36 > 0:28:40to stop the decline of traditional skills.
0:28:40 > 0:28:43And this is especially essential for the survival of Barrow.
0:28:43 > 0:28:46This is the captain's cabin space. Ooh!
0:28:50 > 0:28:53This is a call signal station.
0:28:53 > 0:28:58So if the power goes down on the boat and you can't contact other areas,
0:28:58 > 0:28:59this will have a handset on it.
0:28:59 > 0:29:02So it's like a wind-up phone.
0:29:02 > 0:29:06Apprentices always work with someone already qualified,
0:29:06 > 0:29:07known as a journeyman.
0:29:09 > 0:29:12I basically get a step-by-step guide through how to do something
0:29:12 > 0:29:16until I've learned - until I'm confident I can do it myself,
0:29:16 > 0:29:21and then I do them on my own. But I've never done one of these before, so Carl'll tell me what to do.
0:29:33 > 0:29:37These cables are going to be going into the tops of the terminals,
0:29:37 > 0:29:39which are connected to the bottoms of the terminals.
0:29:39 > 0:29:43All these colours go up the side and then they're all connected in there.
0:29:43 > 0:29:47We've got blue and black, red and black, then there's three white and black ones.
0:29:47 > 0:29:51- We'll be able to work out on the drawing which one goes where. - So just them ones?
0:29:51 > 0:29:52Yeah.
0:29:53 > 0:29:55- What next?- Three and four.
0:29:55 > 0:30:00These are the first submarines we've built for ten years and a lot of the skills have been lost.
0:30:00 > 0:30:04We had a spell with no apprentices coming through. We've had to start it up again.
0:30:04 > 0:30:07If you didn't have apprentices, you'd be struggling in the future.
0:30:07 > 0:30:10This is the big employer of the town.
0:30:10 > 0:30:11We need this to keep going.
0:30:11 > 0:30:14- Good?- All right. Yeah.
0:30:14 > 0:30:16Sorted.
0:30:16 > 0:30:18Erin did well. She looked at it, she did well.
0:30:18 > 0:30:21- Nice and neat. So, good job. - We opened it and there's
0:30:21 > 0:30:24loads of terminals and I thought, "Looks complicated."
0:30:24 > 0:30:29But once you read the drawing and understood it, it was pretty easy.
0:30:29 > 0:30:31While the teams continue to finish the inside,
0:30:31 > 0:30:35a very special process is beginning on the outside.
0:30:35 > 0:30:39The surface of the boat is covered with around 40,000 rubber tiles,
0:30:39 > 0:30:41designed to make the boat almost invisible.
0:30:41 > 0:30:45The rubber absorbs and then breaks up enemy sonar waves,
0:30:45 > 0:30:49stopping the signal returning and giving the Astute's position away.
0:30:49 > 0:30:53This rubber blanket also gives added sound insulation,
0:30:53 > 0:30:55making the submarine even quieter.
0:30:55 > 0:30:59Each submarine will spend around five years inside the Devonshire Dock Hall,
0:30:59 > 0:31:04before being removed and lowered into the dock outside by a massive ship lift,
0:31:04 > 0:31:08capable of handling vessels weighing more than 16,000 tonnes.
0:31:09 > 0:31:11Once in the Wet Dock,
0:31:11 > 0:31:14the submarine can be fine-tuned and finished.
0:31:35 > 0:31:37- Stop!- Unlocked.
0:31:38 > 0:31:40The weapons storage department,
0:31:40 > 0:31:45or torpedo room, is where weapons are loaded, stored and fired from.
0:31:45 > 0:31:49The Astute is armed with Spearfish torpedoes, that have
0:31:49 > 0:31:52a range of over 65 kilometres and weigh two tonnes each,
0:31:52 > 0:31:54and Tomahawk cruise missiles,
0:31:54 > 0:31:58able to accurately hit targets more than 1,000 kilometres inland.
0:31:58 > 0:32:02However, as an attack submarine, the Astute is not built to carry
0:32:02 > 0:32:04the controversial Trident missile system.
0:32:04 > 0:32:07Today, the crew are engaging in a war-game exercise,
0:32:07 > 0:32:11to test that all the equipment is talking to each other correctly.
0:32:11 > 0:32:13The plan today is to run three scenarios.
0:32:13 > 0:32:17These scenarios will test all aspects of the system,
0:32:17 > 0:32:20both, er, physically
0:32:20 > 0:32:23and the crew as well. It will test them as well.
0:32:23 > 0:32:26OK, listen up, guys. This is your brief. Your task.
0:32:26 > 0:32:29You've been allocated a patrol area in the Norwegian Sea
0:32:29 > 0:32:32with an assigned role of surveillance and intelligence gathering.
0:32:32 > 0:32:34Patrol the area and attempt to covertly trail
0:32:34 > 0:32:38any deploying submarines which you detect and classify.
0:32:38 > 0:32:41You are to maintain a fire control solution at all times whilst on the trail.
0:32:41 > 0:32:44If you detect a Delta Four preparing for a weapon firing,
0:32:44 > 0:32:47you are to conduct a simulated Spearfish engagement,
0:32:47 > 0:32:50including water shots to ensure counter-detection.
0:32:50 > 0:32:53You have two hours and 30 minutes to save the world.
0:32:55 > 0:32:57Dangerous submarine contact.
0:32:57 > 0:33:02The control room up here is where we prepare the fire control solution for firing a weapon
0:33:02 > 0:33:06and then down below in the weapon stowage compartment, or bomb shop,
0:33:06 > 0:33:08that's where we actually fire the weapons from.
0:33:08 > 0:33:12It's simulating the submarine being used for what it's intended.
0:33:12 > 0:33:13Classified Oscar.
0:33:13 > 0:33:17'Stand by Spearfish tactic, track 35 is targeting Classified Oscar.
0:33:17 > 0:33:19'From two tube.'
0:33:19 > 0:33:21Valid active contact.
0:33:21 > 0:33:24Valid active contact. Weapon two.
0:33:24 > 0:33:26DISTORTED SPEECH OVER RADIO
0:33:31 > 0:33:34The command system uses its various algorithms
0:33:34 > 0:33:36to work out where we think the target's going to be.
0:33:36 > 0:33:40And then once we've got a good fire control solution on the target,
0:33:40 > 0:33:41we'll try and fire a weapon at it.
0:33:41 > 0:33:46Valid active contact bearing 146, range 10,700 yards.
0:33:46 > 0:33:50- That is the target. Continue the attack.- Roger. Continue the attack.
0:33:50 > 0:33:52Starboard fire. Track 35.
0:33:52 > 0:33:54Starboard fire. Track 35.
0:33:59 > 0:34:00Weapon is in weapon mode.
0:34:00 > 0:34:03It's gone very well. I think the crew were very impressed
0:34:03 > 0:34:06and certainly, our team were very impressed.
0:34:06 > 0:34:10We all worked very hard. It's been a very long day. I think we've all got something out of this.
0:34:14 > 0:34:16With the command deck fully operational,
0:34:16 > 0:34:21the last major engineering feat to overcome is also the most difficult.
0:34:21 > 0:34:25The submarine's nuclear reactor will need to be switched on.
0:34:31 > 0:34:34Safety is the first priority.
0:34:34 > 0:34:39And the people of Barrow need to be prepared for the unlikely event of a nuclear accident.
0:34:39 > 0:34:41SIREN WAILS
0:34:41 > 0:34:45This is the first time in ten years since we've last operated a nuclear reactor.
0:34:45 > 0:34:50There are plans that have been put in place by the civil authorities that we've signed up to.
0:34:52 > 0:34:55There's a lot of eyes watching how we do our business here.
0:34:55 > 0:34:57There's a lot of auditing done on a very regular basis.
0:34:57 > 0:35:01So, yes, we're watched and very open in what we do here.
0:35:03 > 0:35:07Doesn't bother me. It's just part of the town and part of my growing up.
0:35:09 > 0:35:12If there's an emergency, they will sound that buzzer.
0:35:12 > 0:35:15If you hear that buzzer going, you know there's something wrong.
0:35:15 > 0:35:19The shipyard sends out leaflets -
0:35:19 > 0:35:22what to do in an emergency.
0:35:22 > 0:35:24Innocuous looking packet of tablets.
0:35:24 > 0:35:28These tablets are there to protect your thyroid.
0:35:28 > 0:35:32but we've never had a nuclear emergency in all those years.
0:35:32 > 0:35:36So, why worry? I think what people worry about round here
0:35:36 > 0:35:39is where the next shilling's coming from to buy the tea.
0:35:39 > 0:35:41STEEL DRUMS PLAY "In The Mood"
0:35:44 > 0:35:48For a town that's been building nuclear submarines for 50 years,
0:35:48 > 0:35:53testing the warning systems is just a routine event and doesn't interrupt everyday life.
0:35:57 > 0:36:01Usually I'm wearing big blue overalls, nice and baggy.
0:36:01 > 0:36:04But you can't have a carnival without all the sparkles.
0:36:04 > 0:36:08This is obviously a lot sparklier and a lot more colourful!
0:36:08 > 0:36:11It's nice to be able to come out of work and have a totally different life.
0:36:11 > 0:36:15You have to have a different personality to be able to get on with the guys.
0:36:15 > 0:36:18But it's good to come and have a little break from it.
0:36:18 > 0:36:20I don't miss out on any of the girly stuff,
0:36:20 > 0:36:22because I see these twice a week.
0:36:22 > 0:36:26- What do you think about me working in the yard?- I think it's cool!
0:36:26 > 0:36:29- Why is it cool? - Because you can fix my plugs.
0:36:31 > 0:36:33That's all I'm good for, is it? Fix your plugs!
0:36:42 > 0:36:44Landing is fine, land at your discretion.
0:36:44 > 0:36:46The wind 180, four knots.
0:36:46 > 0:36:48'Roger that.'
0:36:50 > 0:36:52As the summer turns into the autumn,
0:36:52 > 0:36:54boat one is nearing the end of its testing phase
0:36:54 > 0:36:57and closer to having its reactor switched on.
0:36:57 > 0:37:01So it's now coming under close scrutiny by the man charged with
0:37:01 > 0:37:06ensuring the vessel is safe and ready to be delivered to the Royal Navy.
0:37:06 > 0:37:09- It's all kind of coming together. - Right. Thank you.
0:37:09 > 0:37:10We're going to test everything.
0:37:10 > 0:37:12Cooking a curry and lasagne.
0:37:12 > 0:37:15We're going to serve it to an admiral in about an hour's time.
0:37:18 > 0:37:21I've been on two different types of submarines
0:37:21 > 0:37:25and this is the biggest gallery I've ever been on. It's absolutely massive.
0:37:25 > 0:37:30The admiral has come to hear first-hand how close they are to switching the nuclear reactor on
0:37:30 > 0:37:32and taking the submarine to sea.
0:37:34 > 0:37:37Hello. How do you do? Hello, Coxon.
0:37:37 > 0:37:41Generally, just a normal working environment, it's not bad at all.
0:37:41 > 0:37:45It's not so hot that you can't work in it.
0:37:45 > 0:37:47- Where are we having lunch? Here? - In here, sir.- Good.
0:37:47 > 0:37:52- Him having a bit of dinner is a bit of a bonus for him.- I'm keen to hear what it's like at grassroots level.
0:37:52 > 0:37:57The main priority is just to make sure everything works and we can actually work in here.
0:37:57 > 0:38:03Which other defects have emerged that give you a sense that we're going to have a tricky month ahead of us?
0:38:05 > 0:38:08I'm in charge of purchasing submarines for the Ministry of Defence.
0:38:08 > 0:38:11It's my job to make sure that the purchasing operation
0:38:11 > 0:38:12is well-founded
0:38:12 > 0:38:14and that we're...
0:38:14 > 0:38:17That the programmes that we're hearing from the company
0:38:17 > 0:38:21are sensible and real and we're getting value for money out of them.
0:38:21 > 0:38:25Wrestling the boat from the dock - that sounds like an negative thing -
0:38:25 > 0:38:31but wrestling the boat out of the hands of the dockyard that have loved it is what we do.
0:38:31 > 0:38:34After his inspection and discussions with the crew,
0:38:34 > 0:38:38Admiral Lister needs to take his findings to the managers of the shipyard.
0:38:38 > 0:38:42We have meetings with Admiral Lister at least once a fortnight.
0:38:42 > 0:38:45We had originally hoped to be ready to go to sea late summer.
0:38:45 > 0:38:47We're a little bit later than that now.
0:38:47 > 0:38:51We've had no fundamental issues, but we have had some minor teething problems and difficulties.
0:38:51 > 0:38:55Nothing major, but a few obstacles that we've had to overcome.
0:38:55 > 0:38:59The meeting will last late into the night.
0:39:01 > 0:39:05Obviously, we're interested in your reflections on the visit on the boat we've just done.
0:39:05 > 0:39:10Then I wouldn't mind quickly going through the agenda for tomorrow, to make sure we've got that done.
0:39:10 > 0:39:13Right. In terms of technical progress,
0:39:13 > 0:39:18where you've handed over compartments, they're impressive.
0:39:18 > 0:39:23The wardroom and the junior eights are very good indeed.
0:39:23 > 0:39:27The people who've fitted them out should be congratulated.
0:39:27 > 0:39:32Overall, though, I'd have expected you to make more progress in handover.
0:39:32 > 0:39:35My quiz to Alan and Paul as they showed me round was,
0:39:35 > 0:39:38"Why haven't you moved on forward more than this?"
0:39:38 > 0:39:42And they were telling me they've been clearing defects like nobody's business.
0:39:42 > 0:39:46Yeah, the word "defects" is something we've debated.
0:39:46 > 0:39:50In the construction industry, I think they use the word "snagging".
0:39:50 > 0:39:54I know in the US, they the word "unsats" - unsatisfactories.
0:39:54 > 0:39:59We use the word defects. Anything that doesn't comply with the requirements or the specification.
0:39:59 > 0:40:03So the vast majority of defects are pretty modest. They're things like paint spills,
0:40:03 > 0:40:06tally plates missing, chips in varnish. Those sorts of things.
0:40:06 > 0:40:11That's my challenge to you. Is this going at the pace that we need it?
0:40:11 > 0:40:14We need this submarine. We absolutely need this submarine.
0:40:14 > 0:40:18It's hugely frustrating - not just for me, but for the whole company.
0:40:18 > 0:40:22We really do want to see Astute go to sea. We want to show what a capable submarine it is.
0:40:22 > 0:40:26The Astute is almost four years late on its delivery
0:40:26 > 0:40:30and estimated to be overspent by around £800 million.
0:40:30 > 0:40:35BAE Systems inherited some of these problems back in the 1990s,
0:40:35 > 0:40:38before they owned the company.
0:40:38 > 0:40:42Design and contractual issues hampered the early stages of the project
0:40:42 > 0:40:47and apprentice schemes had been stopped, which meant skills were being lost from an aging workforce.
0:40:47 > 0:40:50In 1999, when they took over the shipyard,
0:40:50 > 0:40:56BAE Systems had to implement new design technology and reintroduce the apprentice scheme.
0:40:56 > 0:41:02Only now is the first of seven vessels about to be delivered to the Royal Navy.
0:41:04 > 0:41:06What drew me to the submarine service,
0:41:06 > 0:41:11particularly as an engineer, was the nuclear aspect.
0:41:11 > 0:41:15I find it quite fascinating that we can produce so much energy
0:41:15 > 0:41:19for a submarine all in such a small tube,
0:41:19 > 0:41:22going around the world for months at a time.
0:41:22 > 0:41:26Doing things that people don't necessarily know about.
0:41:26 > 0:41:29I'm a keen biker. It's a beautiful ride in.
0:41:29 > 0:41:32The Lake District is my favourite place in the country.
0:41:32 > 0:41:35And living in Bardsey is a beautiful little village as well,
0:41:35 > 0:41:37with some special attractions.
0:41:39 > 0:41:43Commander Paul Knight is overseeing the nuclear reactor being switched on -
0:41:43 > 0:41:46the last job before the boat can leave the dock.
0:41:47 > 0:41:50The design of our reactor is confidential.
0:41:50 > 0:41:52We don't want to let the design out
0:41:52 > 0:41:56because it does give indications of the performance of the submarine.
0:41:56 > 0:42:01And also, the technology that's behind it is obviously valuable to the nation,
0:42:01 > 0:42:04and we wouldn't want to share it with other nations.
0:42:04 > 0:42:08You take the reactor critical by taking the control rods out of the reactor core.
0:42:08 > 0:42:11It starts off very low power,
0:42:11 > 0:42:14producing a power which you can barely light a lightbulb with,
0:42:14 > 0:42:18all the way up to full power, which is obviously a confidential figure.
0:42:18 > 0:42:20I can't tell you.
0:42:20 > 0:42:23But is enough really to power a city the size of Southampton, really,
0:42:23 > 0:42:25is the comparison we make.
0:42:27 > 0:42:29It's the first time in ten years
0:42:29 > 0:42:33a nuclear reactor is being switched on anywhere in the UK.
0:42:33 > 0:42:37But the people of Barrow take it in their stride -
0:42:37 > 0:42:40including former shipbuilders who've seen it all before.
0:42:42 > 0:42:45It's just an everyday occurrence for us.
0:42:45 > 0:42:47Not that it happens every day or every week.
0:42:47 > 0:42:51It only happens at the tail-end of the build of a submarine.
0:42:51 > 0:42:55There's never been an accident. The things are totally safe.
0:42:55 > 0:42:57Hopefully. Touch wood.
0:42:57 > 0:43:01It is a bit of a strange thing to be used to, obviously.
0:43:01 > 0:43:05- It's summat you grow up with in the town.- Yeah, I-I-I can't see...
0:43:05 > 0:43:07There's nothing to be frightened of.
0:43:07 > 0:43:08We're all doomed, sir!
0:43:29 > 0:43:31It's Saturday morning,
0:43:31 > 0:43:36September the fifth, and we're starting power range testing today.
0:43:36 > 0:43:38Good morning.
0:43:45 > 0:43:48It's just a day like any other in Barrow.
0:43:48 > 0:43:53But inside the shipyard, the reactor is carefully being switched on and monitored by nuclear engineers.
0:43:56 > 0:43:58OK.
0:44:00 > 0:44:01We've started. That's good.
0:44:01 > 0:44:06That's the first time we've taken a new design of a reactor critical
0:44:06 > 0:44:10on a submarine for ten years as well, so it's a very big milestone -
0:44:10 > 0:44:13not only for the Astute project, but also for the UK as a whole.
0:44:14 > 0:44:17The design of the reactor is top secret,
0:44:17 > 0:44:20but there are some elements that are unclassified.
0:44:20 > 0:44:22It's protected by special shielding
0:44:22 > 0:44:26that weighs around 100 tonnes and protects the crew from radiation.
0:44:26 > 0:44:32It's fuelled with an incredibly radioactive substance, enriched uranium.
0:44:32 > 0:44:37When the reactor is started up for the first time, a neutron is fired at a uranium atom.
0:44:37 > 0:44:40That uranium atom splits, or fissions,
0:44:40 > 0:44:42releasing energy and freeing more neutrons
0:44:42 > 0:44:46that trigger the same process of splitting in surrounding uranium atoms.
0:44:46 > 0:44:49Once this chain reaction becomes self-sustaining,
0:44:49 > 0:44:55the reactor is said to be critical and is generating an enormous amount of heat.
0:44:55 > 0:44:58Once we've ensured the design is correct, the instrumentation is correct,
0:44:58 > 0:45:01we then move up in power in gradual steps,
0:45:01 > 0:45:05resulting in, in two weeks' time, full power operations.
0:45:06 > 0:45:12The huge amount of energy the reactor is creating is used to heat water.
0:45:12 > 0:45:15The water, under extremely high pressure,
0:45:15 > 0:45:18which prevents it from boiling, passes a heat exchanger,
0:45:18 > 0:45:22which contains another circuit of water at a much lower pressure.
0:45:22 > 0:45:26This water DOES boil and creates steam.
0:45:26 > 0:45:31The steam drives turbines and the turbines generate all the power the submarine needs.
0:45:31 > 0:45:35The Astute is, in part, an old-fashioned steam engine -
0:45:35 > 0:45:38though coupled with 21st Century nuclear technology.
0:45:40 > 0:45:44Yeah, it's been not just a tough week - it's been a tough few months, really, getting here.
0:45:44 > 0:45:50Yeah, definitely. It's a relief, I guess, for a lot of people who've worked very, very hard.
0:45:50 > 0:45:52And fingers crossed, it should all go smoothly
0:45:52 > 0:45:55and we're one step closer to exiting Barrow
0:45:55 > 0:45:59and taking the submarine to sea and handing it over to the Royal Navy.
0:46:05 > 0:46:07But as that moment gets closer,
0:46:07 > 0:46:12an unexpected and unforeseen obstacle appears from nowhere.
0:46:12 > 0:46:15And this one could stop the submarine leaving Barrow altogether.
0:46:17 > 0:46:21This is number one seagate, a flap gate by design. It's rather like a drawbridge.
0:46:21 > 0:46:24At the moment, she's laying down in the recess.
0:46:24 > 0:46:28We're unable to shut the gate and make this area non-tidal.
0:46:28 > 0:46:33The submarine only has a certain amount of time to get from the dock to the deep water.
0:46:33 > 0:46:37And without the gate, this timing is next to impossible to control,
0:46:37 > 0:46:40meaning the Astute's exit would become a huge gamble.
0:46:40 > 0:46:45The only way we can take the submarine out now, with one gate out of operation,
0:46:45 > 0:46:48is to time it precisely such that we're in the lock
0:46:48 > 0:46:51at the right height of tide and then take her straight out to sea.
0:46:51 > 0:46:55You then have to accelerate the exit speed through the channel.
0:46:55 > 0:47:00You'd be doing handbrake spins round the corner. It's just not something we would consider.
0:47:03 > 0:47:06With the risk of grounding the submarine a serious one,
0:47:06 > 0:47:09the only choice is to raise the lock gate from the seabed -
0:47:09 > 0:47:13and although the gate is actually owned by Barrow's Port Authority,
0:47:13 > 0:47:17everybody agrees to work together to find out why it isn't working.
0:47:17 > 0:47:20And then hopefully fix it.
0:47:20 > 0:47:24With daylight, the fault is clearly evident.
0:47:24 > 0:47:28This is the side one where you can see a crack on the north side.
0:47:28 > 0:47:32On the far side, this actually sheered off completely.
0:47:32 > 0:47:34It's a big pain, yes. It's a lot of work.
0:47:35 > 0:47:39It's a mammoth task - the gate is over 20 years old -
0:47:39 > 0:47:42but a team of engineers will have to figure out a way to fix it.
0:47:42 > 0:47:46We do want the nuclear submarine going out and so we have a very vested interest
0:47:46 > 0:47:49in getting this gate up and running and operable.
0:47:50 > 0:47:53It's been a few weeks now since you guys have been in town.
0:47:53 > 0:47:58The gate has moved on significantly from where we were three weeks ago.
0:47:58 > 0:48:03The main issue we had was the fact that this bracket here had failed.
0:48:04 > 0:48:06When we recovered the gate,
0:48:06 > 0:48:09we weren't given an awful lot of surprise in terms of
0:48:09 > 0:48:14the extent of the work. We have fitted initial brackets to the structure,
0:48:14 > 0:48:18basically just to make the structure a bit more integral.
0:48:18 > 0:48:22The gate may be fixed, but the job isn't over.
0:48:22 > 0:48:27It's no easy task to re-install the 324-tonne piece of steel.
0:48:27 > 0:48:31It's about the same position it was in when we took it out about two and a half months ago.
0:48:31 > 0:48:33It's a drawbridge-action gate.
0:48:33 > 0:48:36Four times a day, it's cycled - on each tide.
0:48:36 > 0:48:39It's operated from the winch-house, which is located just behind.
0:48:39 > 0:48:45For the next two days, divers and engineers will work around the clock to hit their deadline...
0:48:45 > 0:48:48Without that gate in place, this submarine will not leave Barrow.
0:48:48 > 0:48:52..until it's back where it belongs.
0:49:01 > 0:49:04It's gone very close to programme and most programmes slip quite a lot.
0:49:04 > 0:49:10But this one hasn't slipped too much and today's the big day. It is a big sigh of relief.
0:49:10 > 0:49:14With the gate back in place and the dock fully functional,
0:49:14 > 0:49:18there's nothing left to stop the Astute from finally leaving Barrow.
0:49:18 > 0:49:23Except the weather. And the events of the last few months mean the warm summer is a distant memory.
0:49:23 > 0:49:26She will be sailing in November.
0:49:27 > 0:49:31Commander Andy Coles, the captain of the boat, is preparing his crew for the exit.
0:49:33 > 0:49:37We're just doing the final preparations and final checks, ready to sail tomorrow.
0:49:37 > 0:49:40I'll show you as much as I can within the bounds of legality.
0:49:40 > 0:49:42Welcome onboard.
0:49:42 > 0:49:45Just come this way, please.
0:49:48 > 0:49:50We're in the centre of the control room
0:49:50 > 0:49:53and in front of me, I've got ship control.
0:49:53 > 0:49:56To the left, I've got the sonar and to the right, the combat system.
0:49:56 > 0:50:00This is where I sit and when I'm not here, where the officer of the watch sits.
0:50:09 > 0:50:12And this is my cabin. This is where I sleep and work.
0:50:12 > 0:50:16So I spend my time between the control room and here.
0:50:16 > 0:50:22I have screens here which show me the tactical picture and I can see what's going on on the periscope.
0:50:22 > 0:50:26I'm now converting my chair into the bunk, where I sleep at night.
0:50:29 > 0:50:35I've got communications right next to me and everything's been aligned up so it's above the level of the bunk,
0:50:35 > 0:50:39so in bed when they call me, I can see everything from bed. So it's quite good.
0:50:48 > 0:50:51You can tell what day of the week it is by the food.
0:50:52 > 0:50:55For example, you always have fish and chips on a Friday.
0:50:55 > 0:50:58And you get to look forward to those nights as well.
0:50:58 > 0:51:01Get all the ugly ones out. This is the senior eights' mess.
0:51:01 > 0:51:03If you'd like to follow me.
0:51:03 > 0:51:05OK. This is the senior eights' mess.
0:51:05 > 0:51:07This is one of the three messes we have onboard.
0:51:07 > 0:51:10On the other side of the corridor, the junior eights' mess -
0:51:10 > 0:51:12exactly the same, but this is for the junior eights.
0:51:12 > 0:51:14It's a little more homely now.
0:51:14 > 0:51:19We've gone nice chairs and more comfortable living arrangements.
0:51:19 > 0:51:22It's got a PlayStation, Xbox, big telly, media centre,
0:51:22 > 0:51:26and it's just coming together now, so we're all ready to go to sea in all respects.
0:51:34 > 0:51:38I think you have to have a certain temperament to be a submariner.
0:51:38 > 0:51:42You have to be able to get on with people and work in a very small space.
0:51:42 > 0:51:46We don't tend to be quite so clipped and so formal as other areas of the Navy.
0:51:46 > 0:51:51It's just a matter of the environment we live in. The senior eights live in two different mess decks.
0:51:51 > 0:51:54This is one of them. We utilise the maximum amount of space,
0:51:54 > 0:51:58using three racks on either side.
0:51:58 > 0:52:00Each man has at least one locker,
0:52:00 > 0:52:02and underneath each bunk is stowage as well.
0:52:02 > 0:52:05But we're experts at living on the minimum amount of clothing.
0:52:11 > 0:52:16We're up on the forward navigation position, commonly known as the bridge on the submarine.
0:52:16 > 0:52:20As you can see, we get a very good view from here.
0:52:20 > 0:52:23It's even more precise, I think, than being on the bridge of a ship
0:52:23 > 0:52:26because you can feel the elements working with you or against you.
0:52:26 > 0:52:29You're able to take action against them quickly.
0:52:30 > 0:52:32Tomorrow represents a really key point for us,
0:52:32 > 0:52:36wich is the move away from this dock down to Ramsden Dock and so
0:52:36 > 0:52:42therefore with the tugs' assistance, we'll be going through that bridge and down to Ramsden Dock tomorrow.
0:52:42 > 0:52:46Clearly trying to sail in mid November is a risk with the weather.
0:52:46 > 0:52:49And the weather forecast over the next two days is not ideal.
0:52:49 > 0:52:52We've already got a freshening wind which we can feel in our hair now.
0:52:52 > 0:52:55It's going to get stronger over the next 24 hours.
0:52:55 > 0:53:00But everybody's attention is on us at the moment. This is a key point for the Royal Navy, bringing Astute out.
0:53:00 > 0:53:05I get that wrong, I'm certainly aware of the amount of scrutiny that will be coming down on me.
0:53:13 > 0:53:15It's November the 14th, 2009.
0:53:15 > 0:53:19And the first new British submarine for 10 years
0:53:19 > 0:53:23is about to sail out into the open sea for the very first time.
0:53:23 > 0:53:27Originally planned for the summer, the submarine's last hurdle to exit
0:53:27 > 0:53:31is the uncertainty of the British weather.
0:53:31 > 0:53:33Submarines manoeuvre extremely well underwater.
0:53:33 > 0:53:39But on the surface, they're not quite so good at manoeuvring, so we need some tug assistance.
0:53:39 > 0:53:42They're going to bring alongside four very powerful tugs
0:53:42 > 0:53:46and then we will manoeuvre the submarine through the lock system,
0:53:46 > 0:53:50under the Michaelson Road Bridge, round to Ramsden Dock in preparation for exit.
0:53:58 > 0:54:01There has been a lot of effort from everyone involved here.
0:54:01 > 0:54:05It's been fraught with interesting conversations and emotions that have come out.
0:54:05 > 0:54:07The crew are ready, the tugs are ready.
0:54:07 > 0:54:12The wind has finally dropped. So we've got one window of opportunity before it starts getting dark.
0:54:12 > 0:54:13So, it's a good day.
0:54:56 > 0:54:58It's quite narrow here -
0:54:58 > 0:55:00it's 28 metres wide - so it is quite a challenging thing.
0:55:00 > 0:55:04You can see the challenge to be able to get through this narrow gap.
0:55:30 > 0:55:33We've been eating, drinking, breathing the submarine
0:55:33 > 0:55:35and getting it ready for this moment.
0:55:35 > 0:55:38Now that we can step back and watch it go through,
0:55:38 > 0:55:40it's really a great moment, actually.
0:55:51 > 0:55:54It's something that the country should be really proud of.
0:55:54 > 0:55:58The first time that we've launched a new submarine out of here for ten years.
0:55:58 > 0:56:00It's a hell of an achievement, actually.
0:56:18 > 0:56:20The whole process will take two days,
0:56:20 > 0:56:25but at 9.15 on Sunday 15th November,
0:56:25 > 0:56:29the gate holding back the sea has been safely lowered
0:56:29 > 0:56:32and the submarine leaves Barrow for the first time.
0:56:33 > 0:56:35She'll never return.
0:56:53 > 0:56:55Once free of shallow water,
0:56:55 > 0:56:58the tugs will depart and her reactor will take over,
0:56:58 > 0:57:01silently powering the Astute through the ocean.
0:57:05 > 0:57:09Started off as a team leader on the Astute that's just gone out.
0:57:09 > 0:57:11Fantastic pride.
0:57:11 > 0:57:14That's what I felt. We want to see more of these.
0:57:14 > 0:57:17And not with ten-year gaps, either.
0:57:23 > 0:57:28I work on boat two. We need to make sure we knuckle down and we can have a day like this in years to come.
0:57:35 > 0:57:38It was built slowly and carefully by a lot of dedicated people.
0:57:38 > 0:57:40It's a wonderful thing to see it go.
0:57:40 > 0:57:44I was surprised, actually, to see how fast it was cruising along there.
0:57:45 > 0:57:49It's taken 14 years to get to this moment.
0:57:49 > 0:57:53But for almost 5,000 people in the shipyard,
0:57:53 > 0:57:55tomorrow is another working day.
0:57:55 > 0:58:00They'll clock on as usual and continue building the next Astute submarine -
0:58:00 > 0:58:04one of the world's most complicated and secretive machines.
0:58:42 > 0:58:46Subtitles by Red Bee Media Ltd
0:58:46 > 0:58:48E-mail subtitling@bbc.co.uk