During filming, an accident with a wind machine decapitated one stage hand and severely hurt another, splattering star actress Aishwarya Rai Bachchan with blood. She suffered from shock and was cared for by Salman Khan.
Manoj Bajpai was offered the role of Chunni Babu right before Jackie Shroff signed it. Manoj refused on the grounds that he was playing lead roles in all his films and doing a supporting role would hurt his saleability.
Normally, two or three generators would have been used for this film, but this production used 42. This caused the marriages in Mumbai a lot of panic, since all the generators were used for the sets. The film also used 2,500 lights, 700 light men and an infinite number of junior artistes. By the time Zamindar Bhuvan's haveli had to be designed, Bhansali's budget was eaten up.
Ismail Darbar and Sanjay Leela Bhansali spent two-and-a-half years to compose the music. Each song, being complicated in their structure, had to be mixed eight to nine times, but the recording took only ten days.
The set of Chandramukhi's kotha was constructed around a lake. Consequently, the water in the lake kept drying up and gallons of water had to be regularly filled in. Moreover, the bridge built across the lake had a tendency to sink at all the wrong times.
Paro's delicate stained-glass house was erected from November to June - safe, non-monsoon months, Bhansali reckoned. During those months, there were four unprecedented rain showers, which caused the colors in the stained glass to fade, and they had to be retouched regularly. Moreover, trolleys were used over the floors of the house, which led to a lot of chipping.