Case Study: The Real Noah's Ark (Channel 4)

Building a Biblical Legend. Literally.

  • Project: The Real Noah's Ark (Secret History)
  • Format: Specialist Factual / Engineering Documentary
  • Client: Blink Films (UK) / Channel 4 / PBS / Nat Geo
  • Credit: Line Producer (India) / Project Manager
  • Location: Kerala (Backwaters)
  • Duration: 8 Months (Construction & Shoot)

Construction of the real Noah's Ark in Kerala backwaters for Channel 4 documentary, managed by Goa Film Services.

The Challenge: Ancient Blueprints vs. Modern Physics

When Blink Films approached us, they had a tablet—a 3,700-year-old Babylonian clay tablet—and a question: Could the instructions on this rock actually float?

The tablet described a circular Ark, made of reeds and bitumen. The production needed to build it, for real, at scale.

The initial creative direction pointed toward the coracle builders of Karnataka. However, we recognized immediately that the Karnataka coracles, while traditional, were too small-scale for the structural demands of a biblical Ark. Sticking to the original plan would have resulted in a sinking ship and a sinking production.

Furthermore, this wasn't just a shoot; it was a construction project. It required employing a massive workforce for nearly a year, navigating India's complex labor laws, and managing a high-risk build in a humid, aquatic environment.

The Solution: The "Shipyard" Pivot

We shifted the entire production strategy from Karnataka to Kerala, leveraging the state's centuries-old industry of Kettuvallam (houseboat) building. These craftsmen didn't just weave baskets; they built floating homes.

  1. Employment as Infrastructure

We didn't just hire "extras"; we became a construction firm. We directly employed and pay rolled 40 master craftsmen for the 8-month duration.

  • The Compliance Shield: In India, long-term employment triggers a minefield of government compliance. We managed the Provident Fund (PF), Employees' State Insurance (ESI), and Tax Deducted at Source (TDS) for every single worker. We issued notarized contracts, protecting the UK production company from any liability or labor disputes.
  1. Remote Project Management

The UK unit couldn't station a Producer in Kerala for 8 months. We filled that void.

  • The "Eyes on the Ground": After the initial recce and setup, the UK team returned to London. For the bulk of the build, GFS acted as the on-site production office. We managed the boatyard, and utilized local crews to shoot interviews, progress logs and time-lapses, shipping the footage back to London. We ensured the Ark was ready for its close-up when the Blink team returned for the launch.
  1. Sourcing the Unsourceable
  • We scouted dozens of boatyards to find a facility that offered the right mix of cinematic aesthetics and industrial capacity. We sourced tons of specific reeds, coir, and bitumen, managing a supply chain that had to look "ancient" but function with modern reliability.

The Outcome

The Ark floated. The documentary, The Real Noah's Ark (aired as Noah's Ark: The New Evidence in the US), became a ratings hit for Channel 4 and PBS, praised for its ambitious scale and scientific rigor.

We proved that we can manage more than just cameras; we can manage heavy industry. We delivered a complex, high-liability construction project on time, legally compliant, and under budget, allowing the client to direct the show from London while we built the set in India.

What The Client Said

"Tony was a real can do guy. He fixed everything from kit to hotels and cars, but also proved really useful as a second camera op on a couple of shoots. Great guy, nothing is too much trouble!!"

- Laura Warner, Senior Producer | Blink Films

 

The Official Channel 4 Trailer...

 

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