Playland Amusement Park
Project Description
Property History
Playland, often called Rye Playland or Playland Amusement Park, is an 280-acre amusement park located in Rye, New York and owned by the Westchester County government. Constructed in 1928 and designed by Frank Darling, veteran park manager with experience at Coney Island, NYC architectural firm Walker & Gillette, and landscape architect Gilmore D. Clarke, Playland was the first planned amusement park in the country.
Project Scope
The project consisted of restoring and replicating historic exterior pier mounts and wall fixtures located throughout the exterior grounds of the park. Each existing historic fixture was individually inspected, removed, and packed on-site. Additionally, 100+ wall and pier mount fixtures were cast replicated to match the original historic lights.
The original historic post mount fixtures were suffering from severe rusting and finish deterioration. To remedy this, the fixture bases were placed in our burnoff oven and then media blasted to remove all debris and the existing finish. Each original and replicated post mount, consisting of the base, crown, and finial, received new custom white, high durability powder coat finishes. Grand Light engineers designed a new prismatic soda lime glass diffuser for the post mounts, which matched the original acorn-style glass but with improved stability, easier installation and maintenance. All fixtures were wired with UL listed components, HIPOT tested in accordance with UL standard 1598, and partially assembled prior to on-site delivery and installation.
Additionally, Grand Light restored a number of historic exterior wall sconces. Suffering from severe rusting, cracking, and general deterioration, many of these fixtures required significant mechanical repairs. Our artisans made efforts to clean and conserve the existing antique verde patina finishes, while some fixtures needed to be refinished in a verde green patina with a protective top coating. Each sconce received a new acrylic diffuser, and was rewired with a new electrical assembly with an LED uplight.
In addition to the post mount fixtures, we restored multiple non-electrified column mounted exterior fixtures. These fixtures were partially disassembled and surface treated to restore the original antique copper verde finish. The existing amber diffusers were also thoroughly cleaned and conserved for the restored fixtures.
Services Performed
On-Site Packing, Crating, & Transportation
Grand Light frequently transports lighting fixtures using our own box trucks, flatbeds, and custom-built trailers that are designed specifically for safe transport. Our team packs all components with custom-built crates catered to each fixture in our factory. Each crate is packed and properly labeled with all necessary information per fixture type, including loose components, damages/deficiencies, and proper component placement/alignment.
Lighting Design & Engineering
Our process begins with reviewing existing documentation including sketches, architectural drawings, historical photographs, and an on-site inspection to gather the full scope of the project requirements. From there, Grand Light will develop a detailed proposal. As required Grand Light conducts research to assure the historical accuracy of all historic projects.
The creation of Custom Drawings, Modeling, Simulation, and Rendering is an important part of the process when it comes to the production of custom lighting. Whether it be a replication or modification of an existing lighting fixture, the client’s design, or a creation by Grand Light’s engineering team, our designs will serve as the blue print for our production process.
Our designs and subsequent mock-ups address the smallest of detail, allowing our clients to fully visualize the fixture before it goes into production, which reduces the possibility of error, and allows Grand Light to fulfill its commitment of delivering high quality lighting fixtures on schedule.
Material Fabrication
Grand Light has created custom lighting fixtures of every style and for every application. Our team of professional metal workers excel in Forming, Forging, Spinning, Stamping, and Hydroforming various materials such as Steel, Aluminum, Stainless Steel, Brass, Bronze, and Copper.
Grand Light’s production process in machining and manufacturing custom lighting fixtures and components in both large and small quantities; from minor components to the complete fabrication of full sized lanterns or other custom lighting fixtures, our artisans can accommodate any client specification or deadline.
With our automated lathes, stamping, and welding equipment aid in our ability to craft metal components to project specification with unparalleled design, quality, and durability. Our custom lighting team stands confidently behind their work with years of experience and dedication to quality craftsmanship.
Glass and Acrylic Cleaning & Fabrication
Grand Light’s Crystal, Glass, & Acrylic Studio specializes in the cleaning, repair, fitting, custom fabrication, replacement and replication of crystal, glass, and acrylic components of varying types, sizes, and color.
Our extensive cleaning solutions include hand cleaning, abrasive, micro-abrasive, and ultrasonic cleaning technology. Our artisans utilize a proprietary cleaning solution before each component is rinsed and hand polished. We have extensive experience pinning and stringing crystal components on historic and custom lighting fixtures. Utilizing time proven techniques, our artisans install pinning wire, clips, and connecting rings on crystal components in a wide variety of sizes, shapes, and designs.
Our specialists will identify and research any missing crystal or glass component on a historic lighting fixture and offer up a similar or exact grade, size, tint, color, and shape to maintain a fixtures historical integrity.
Grand Light offers a wide variety of custom, high quality architectural glass and acrylic diffusers, available in an array of styles, types, and sizes. Our high quality architectural diffusers are available by custom order and offer unique, one-of-a-kind pieces or replications of an existing design.
Cleaning Systems
Grand Light specializes in commercial luminaire cleaning services, including the utilization of state-of-the-art Ultrasonic, Micro-Abrasive, and Hydrosonic Molecular Impact System (HSMI) Cleaning Technologies. Using our engineered cleaning systems, our artisans are able to eliminate decades of accumulated debris from any lighting fixture or surface.
Grand Light’s Industrial Ultrasonic Cleaning Tanks provide high-frequency sound waves transmitted through liquid to scrub clean the surface of immersed parts. The high-frequency sound waves, typically 40 kHz, agitate the liquid solution of water or solvent, and cause the cavitation of solution molecules.
Our Micro-Abrasive process utilizes fine abrasive media to generate an accurate, precise, and controllable abrasive jet to target and remove material (on the micron level). Our system is so precise it can remove ink from a business card without damaging the card’s surface.
HSMI is Grand Light’s unique, proprietary system includes powerful continuous super high steam production up to 369 degrees Fahrenheit with an integrated wet vacuum system insuring residual moisture and debris extraction. Purified dry vapor steam and integrated vacuum system guarantees spot free crystals and fixture frames.
Surface Preparation
Grand Light specialists perform testing on each fixture to determine the optimal surface profile for powder coat, paint, metal oil, or hot/cold patina application. Our processes utilize a wide range of equipment including Pyrolysis, Burn-Off, Thermal, and Blast Cabinets to remove an existing finish and smooth or roughen a surface.
Our industrial Pyrolysis, Burn-Off, Thermal Ovens and Heaters offer high-temperature, controlled burns for removal or vaporization of finish or foreign material from metal surfaces. Any remaining ash is removed through our blast cabinet services.
Our industrial Media Blast Cabinets are generally used to remove existing material (finish, contaminants, rust, etc.) or smooth/roughen a surface, all without causing damage to the original profile and aesthetic elements. Each cabinet houses a large work area and adjustable turn table to easily maneuver fixture frames and components.
Finish Application & Top Coatings
As a part of the restoration process, our artisans explore the intricate details of preserving the historical integrity of lighting fixtures including color matching and sheen of the original finish. Custom lighting finishes are available in custom painted colors, sheen, and textures as well as custom patina colors on bronze, copper, and brass components.
Our artisans can match any color or finish utilizing a variety of processes involving Powder Coat, Spray, Hot or Cold Patina Custom Recipes and Color Blending an existing finish.
Grand Light exercises meticulous techniques that are unparalleled in the application of Protective Top Coatings including binders, rust, and UV resistant protective metal oils, waxes, and lacquers with various customized sheens and tints.
Replication Casting
Our metalsmiths can fabricate a variety of materials by hand forging or producing components utilizing the Lost-Wax and Sand Casting Processes. Our custom cast metal fixtures offer complex design, quality, and durability.
The Lost-Wax process consists of utilizing existing components replicate intricate detailing, shape, and size through the combination of custom molds, wax patterns, and ceramic shells. This process offers great precision and can replicate components ranging from tiny parts and entire frame castings.
Sand casting is a manufacturing process in which molten metal is poured into a sand mold containing a hollow cavity of the desired shape. After a period of time, the casting cools and solidifies. The sand is then broken away and shaken out.
LED Energy-Efficient Systems
Our Energy-Efficient LED Advantage Systems update the lighting element, wiring, and components to significantly increase the lighting quality of an area while minimizing total energy consumption and reducing maintenance costs. When incandescent lamps are upgraded to an LED system, the result is a room that is up to (3) times brighter, savings up to 80% in annual(recurring) energy costs, and extended operational lifespan.
Improvements can also be achieved through the implementation of photometric testing, intelligent controllers, photocells, motion detectors, and light lifts. All of these, often in combination, can significantly reduce operating costs and provide long term return on investment.
NRTL Testing & Listing
Utilizing only UL listed products, Grand Light’s OSHA NRTL Certified Manufacturer’s Testing and Listing Laboratory strives to ensure only the highest quality of standards go into finalizing each lighting fixture; from the rewiring of luminaires, to the installation of modern lamp technology, and the custom conversion of gas powered fixtures to electric.
Grand Light’s technicians inspect and document any electrical deficiencies on every lighting fixture prior to any electrical component replacement and rewiring. We also offer comprehensive retrofit kits for upgrading existing historic luminaire to take full advantage of modern induction lamping technology. Grand Light’s practice is to perform multiple UL tests on all electrical components and systems to ensure compliance with UL Standards for luminaires.
