Legoland Malaysia

Project Overview

When Legoland Malaysia needed urgent slide restoration, the damage was severe. Years of tropical humidity, intense UV exposure, and heavy guest traffic had deteriorated multiple slides to a critical state. The surfaces had been recoated repeatedly over the years, with some slides buried under as many as eight layers of failed coatings. The park needed a team that could travel internationally, assess the full scope of damage on-site, and deliver a lasting restoration under some of the most demanding environmental conditions in the waterpark industry.

This was not a routine gelcoat job. From day one, the project tested every aspect of our capabilities.

Extreme Surface Deterioration

The slides had been patched and recoated multiple times by previous contractors, creating up to eight layers of incompatible coatings stacked on top of each other. Every layer had to be completely stripped down to the bare gray fiberglass substrate before any new work could begin. On the worst sections, the buildup was so severe it required near-industrial removal methods to cut through.

Equipment Failure in the Field

Midway through the project, our primary spray equipment failed due to the extreme humidity and heat of the Malaysian climate. Operating thousands of miles from our home base, we could not wait for replacement parts to ship internationally. Our team disassembled the machine, diagnosed the failure, and rebuilt it on-site using locally sourced components. The spray system had to be completely re-engineered, including modifying air pressure settings and developing an entirely new application technique to achieve the same factory-quality finish under improvised conditions.

Hostile Working Conditions

Malaysia’s tropical climate created constant challenges for gelcoat application. High humidity affects curing times and adhesion quality. Temperatures fluctuated throughout the day, requiring our team to continuously adjust chemical ratios, catalyst levels, and application windows to ensure every coat bonded properly and cured to full strength.

Despite every obstacle, we delivered. Here is how we approached the project:

Complete surface stripping:  All existing coatings were removed layer by layer until we reached clean, bare fiberglass on every slide surface.

Fiberglass inspection and repair: Once stripped, each surface was inspected for structural damage, delamination, and soft spots. All compromised areas were repaired before any coating was applied.

On-site equipment rebuild:  Our spray system was fully disassembled, rebuilt with locally sourced parts, and recalibrated for a modified high-pressure application method adapted to the conditions.

Climate-adapted gelcoat application: Chemical ratios and application timing were adjusted throughout each day to account for humidity, temperature, and UV index, ensuring proper adhesion and curing on every coat.

Multi-layer gelcoat finish: Multiple coats of premium gelcoat were applied to restore a smooth, high-gloss, durable finish designed to withstand years of tropical conditions and heavy daily use.

The Result

Every slide was fully restored to a like-new condition with a smooth, vibrant gelcoat finish built to perform in one of the most punishing climates in the waterpark industry. The restoration is backed by our industry-leading 5-year gelcoat warranty.

This project stands  as proof of what separates Fiberglass Restoration from every other contractor in the space. When equipment fails, when conditions are extreme, and when the scope is bigger than expected, we do not walk away. We adapt, we solve, and we deliver.

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