Amid the vibrant excitement of Coney Island, Alpine Painting brought new life to one of Luna Park's most beloved attractions, the Thunderbolt roller coaster. Known for its striking orange tracks and exhilarating twists, this 11-year-old steel coaster had begun to show signs of its coastal environment. Rust, fading paint, and grease buildup had dulled its once-vivid appearance.

Luna Park entrusted Alpine Painting with the challenging task of restoring the coaster to its original brilliance while ensuring minimal disruption to park operations. Alpine Painting’s previous experience with amusement park structures, including the Thunderbolt’s white flanges, gave them a competitive edge during the bidding process. Their ability to handle complex projects in public, high-profile locations, safety record, and competitive pricing, made them the ideal choice for Luna Park.

The Challenge: Painting an Operational Ride

Alpine Painting faced a multitude of challenges from the very start. Contractual negotiations delayed the project until April 2024, and the team was restricted to a four-day workweek to accommodate Luna Park’s bustling weekend operations. Creating more challenges to the project, the coaster’s proximity to the ocean resulted in significant salt exposure and moisture, further complicating surface preparation and painting.

The Thunderbolt’s towering 125-foot height and intricate, twisting structure demanded specialized equipment and safety measures. With a tight six-month timeline and a strict budget, the stakes were high, and Alpine Painting’s expertise was tested.

Preparation: Setting the Stage for Success

Surface preparation was a critical first step in restoring the Thunderbolt’s vibrant orange tracks. The team used power washing to remove layers of grease, salt deposits, and contaminants, followed by hand and power tool cleaning (SSPC-SP2 and SSPC-SP3) to tackle rust and stubborn debris. Weekly cleaning sessions were necessary to address new grease deposits from the coaster’s weekend operations.

Alpine Painting’s meticulous attention to detail ensured that the surface was properly prepped for a three-coat system application: a primer and two topcoats designed for durability in harsh coastal conditions. This preparation process enhanced the final result and ensured the coatings’ longevity.

Execution: Expertise in Action

Despite weather delays and equipment challenges, Alpine Painting’s skilled crew of seven navigated the complex structure with precision. Specialized 125-foot boom lifts with articulated jib arms allowed the team to access even the most hard-to-reach areas. Safety was a top priority, with a full-time safety manager overseeing fall protection, lockout/tagout procedures, and hazard analyses.

As work progressed, Alpine Painting demonstrated flexibility and adaptability. When the client requested a specific coating thickness late in the project, the team adjusted their processes to meet the new requirement. Weekly quality control inspections ensured the coatings adhered to client and industry standards.

Adapting to the Unexpected

The project was not without its hurdles. Equipment delays caused by the client’s decision to rent lifts led to lost workdays, while unseasonable rain during the initial phase slowed progress. Additionally, the coaster’s intricate design and tight spaces presented logistical challenges for the crew.

Alpine Painting tackled these issues head-on with clear communication and proactive problem-solving. The team rescheduled workdays to account for weather, increased manpower when necessary, and maintained an open line of communication with Luna Park to ensure all parties were aligned on the project timeline and progress.

Despite the delays and challenges, the Thunderbolt was completed on October 11, 2024, just in time for Luna Park’s fall season. The client, Filippo Andreoni, praised Alpine Painting’s professionalism, reliability, and attention to detail, noting that “clients and employees have noticed significant appearance improvements.” The clean and organized workspace left by the crew further underscored their commitment to excellence.

A Revitalized Icon

The Thunderbolt roller coaster now gleams with its signature bright orange hue, ready to thrill visitors again. The durable coatings not only restored its aesthetic appeal but also provided essential protection against the harsh coastal elements.

This project highlighted Alpine Painting’s ability to combine technical expertise with adaptability and clear communication, overcoming significant challenges to deliver a result that exceeded client expectations. From the iconic backdrop of Coney Island to the vibrant tracks of the Thunderbolt, Alpine Painting has proven once again that they are a leader in commercial painting, capable of tackling even the most complex projects with precision and professionalism.