Project Overview
Alpine Painting undertook the High Falls Gorge Steel Bridges Restoration, a highly complex industrial painting project aimed at revitalizing three bridges, multiple staircases, and walkways at one of the most iconic tourist destinations in New York State. The project required advanced technical expertise, adherence to stringent safety protocols, and a meticulous phased execution plan to ensure uninterrupted visitor access. The restoration was successfully completed on November 16, 2024, ahead of schedule and under budget, despite environmental and logistical challenges.

Project Execution

Start to Finish

The restoration of the three bridges (A, D, and F), staircases (B and C), and a walkway connecting Stair C to E1 commenced with rigorous surface preparation. Surfaces were pressure-washed at 3,500 PSI to remove loose and flaking paint, followed by detailed cleaning using hand and power tools per PCA standards (SP 2 and SP 3).

To prevent contamination, Alpine installed specialized netting systems to capture paint chips. Rusted and bare steel areas were spot-primed before applying a full primer coat, an intermediate coat, and a durable topcoat for long-lasting protection. The project’s phased approach accommodated ongoing visitor access to the attraction, requiring exceptional coordination and workflow management.

Condition of the Structure

The steel structures, dating back to the 1960s, exhibited significant rust and peeling paint. Newer elements added in 2011 after Hurricane Irene were in fair condition, but environmental exposure and age necessitated comprehensive restoration.

Client-Driven Adaptability

Specific Client Requests

The client prioritized maintaining uninterrupted access for tourists. Alpine Painting implemented phased work plans to ensure portions of the site remained operational while others were under restoration. Additionally, half of the third bridge was kept open at all times, allowing visitors to enjoy the most popular viewing area.

When the specified coating materials proved unsuitable for the cold, damp environment, Alpine collaborated with Sherwin-Williams to identify moisture-tolerant, low-temperature products that met the project’s unique needs.

Rapid Mobilization

After a previous contractor withdrew, Alpine Painting mobilized quickly, providing an accurate proposal within weeks. The ability to deploy a skilled crew immediately was critical to meeting the project’s aggressive timeline.

Safety and Environmental Challenges

Safety Plan

The project’s location over a river and waterfall demanded advanced safety measures, including:

• Fall protection: Double lanyard systems and secure tethering of tools.

• Custom containment: Shielding walkways from falling debris and moisture.

• Rigging systems: Suspended scaffolding and rolling platforms ensured worker safety and efficiency.

Environmental Obstacles

The constant mist from the waterfalls required specialized coatings resistant to moisture. Cold temperatures further complicated the project, necessitating low-temperature products for optimal performance.

Results and Impact

On-Time, On-Budget Completion

Despite initial plans to defer work on the third bridge, Alpine Painting’s efficiency allowed the entire project to be completed within 11 weeks, ahead of the anticipated winter snowfall. The project was also completed under budget, a testament to Alpine’s operational excellence.

Client Testimonial

"It has been a pleasure to have Alpine here at High Falls Gorge to paint our steel bridges and walkways. They are doing a super job. It looks great, and they are staying safe at the same time. I am very happy with Alpine and highly recommend them!" – Kathryn Reiss

Innovative Techniques and Tools

Products Used

• Sherwin-Williams Duraplate 235 LV: Exceptional rust protection.

• Armorseal Rexthane I: Durable, weather-resistant finish.

Unique Tools and Equipment

• A custom filtration system ensured environmentally safe pressure washing using water sourced from the river.

• Advanced suspended scaffolding systems provided safe access to bridge undersides.

Key Challenges and Solutions

• Phased Workflows: Maintained visitor access by completing sections sequentially.

• Bridge Accessibility: Worked on one half of the third bridge at a time, ensuring minimal disruption.

• Timeline: Mobilized quickly to address last-minute client needs and completed the project before inclement weather set in.

Conclusion

The High Falls Gorge Steel Bridges Restoration is a showcase of Alpine Painting’s dedication to precision, adaptability, and excellence. The project underscores the company’s ability to deliver superior industrial painting services under challenging conditions, ensuring both structural integrity and visitor satisfaction. This success exemplifies Alpine Painting’s commitment to quality, safety, and client-centric solutions.