In the bustling heart of Newark, New Jersey, the Newark Monorail provides essential transportation services to thousands of commuters daily. However, this lifeline had an issue - its traction-granting grit coating had worn down, causing operational disruptions, especially on rainy days. Recognizing the importance of this challenge, Alpine Painting and Sandblasting undertook a complex and unique project to revitalize the monorail. This case study sheds light on the remarkable journey of refurbishing the Newark Monorail from start to finish.

Project Overview:

The project comprised two phases. In the first phase, Alpine Painting was tasked with reapplying the grit coating to one side of the monorail. Subsequently, in phase two, the opposite side was addressed, effectively covering the entire length of the monorail, from P4 to the airport.

Unique Challenges:

The complexity of this project was multifaceted. The primary challenge was adhering to the client's stringent schedule. The Newark Monorail remained operational on the opposite side, necessitating meticulous planning and safety protocols to prevent electrocution hazards. The team faced the daunting task of working at elevated heights over a highway, with a paramount concern of avoiding material spillage onto the busy streets below.

Innovative Solutions:

To address these unique challenges, Alpine designed and modified specialized carts that safely accommodated their crew on the monorail. The team began with a comprehensive pressure washing, removing contaminants that had accumulated over the years. Various surface preparation methods were employed, including grinding and bristle blasting. The P4 area required cylindric blasting with a blast track.

The most intricate part of the project was the reapplication of the grit coating. The team encountered a setback during phase two, where extensive peeling and coating failures were discovered on the opposite side. This challenge necessitated a change order, enabling Alpine to strip those areas to bare steel. Due to the thickness of the existing coating, specialized ultra-high water pressure (UHP) equipment was employed. After stripping, the team utilized a cylindrical blaster to prepare the bare steel, followed by the application of two coats.

Project Details:

The Newark Monorail, constructed in the 1980s, was in relatively good structural condition. However, the grit coating required reapplication.

Extensive surface preparation was conducted, involving pressure washing, grinding, bristle blasting, and cylindrical blasting, along with specific surface preparation methods.

The project adhered to industry standards such as SSPC-SP 6 Commercial Blast Cleaning, NACE WJ-4/SSPC-SP WJ-4-2021, SSPC-SP 11, and SSPC-SP 6 (WAB)/NACE WAB-3-2015.

Project Outcomes:

Despite the challenges posed by working over water, highways, active train lines, and an airport, Alpine Painting successfully completed the Newark Monorail project, covering more than half a mile. The project was executed safely and efficiently, adhering to the client's schedule.

The completion of phase two notably came ahead of schedule and on budget, underlining Alpine Painting's commitment to delivering high-quality results on time.

Conclusion:

The revitalization of the Newark Monorail showcased Alpine Painting and Sandblasting's expertise in tackling complex, high-risk projects. Their innovative solutions, commitment to safety, and ability to meet demanding schedules set them apart. As the monorail continues to serve Newark, it does so with a fresh grit coating, thanks to the dedicated efforts of Alpine Painting.

Contact Alpine Painting: For inquiries or to learn more about Alpine Painting's services, please visit Alpine Painting's Website or call (866) 596-0349 to discuss your unique project requirements.