A STRICT timetable must be followed to ensure the York Barbican's temporary ice rink is ready in time for rehearsal skating at 4.30pm before the opening show of the Russian Ice Stars' Peter Pan On Ice on December 23.

The work starts the previous day at 9am when technicians arrive with two 45ft trucks. Eight Barbican technicians unload the set and costume truck, known as the dry truck, and start rigging lights, set and flying equipment. At 2pm, the wet truck containing the floor system and surround is unloaded and the task of building the ice rink begins.

Two 15 metre by 15 metre industrial pool liners are laid on the stage and side supports from wood are built to create a large but shallow swimming pool. Inside the pool, 15km of a special flexible rubber pipe is laid and connected to a header system, which is connected to two chiller units on the back of the wet truck.

Two chiller units are used so that in the unlikely event of a total breakdown of one unit, the second will maintain the rink and prevent flooding of the stage and the potential loss of a performance.

The floor system is filled with antifreeze and the pressure is checked. The antifreeze is chilled to minus 15 degrees C – three times colder than a home freezer – and circulated through the floor pipes and at this point the rubber pipes begin to frost over.

Four tons of crushed ice are then spread over the floor pipes, providing a head start in the freezing process. From this point, the rink is sprayed with water every 20 to 30 minutes until it reaches seven to eight centimetres thick in a procedure that takes approximately 14 to 18 hours.

Fourteen tons of ice are used on stage, equivalent to the weight of two double-decker buses; 14,000 litres of water are required to build the rink, enough water to make more than 56,000 cups of tea; the 2,500 litres of antifreeze used in the pipe system would fill 100 Rolls Royce radiators. In all, it takes 140 man hours to build the rink and 30 hours to dismantle it.

Once York Barbican has been transformed into an ice rink, the Russian Ice Stars can present their new adaptation of J M Barrie's fantasy adventure from Decenber 23 to January 3, except Christmas Day and New Year's Day. Performances will start at 7pm on December 23, 29 and 30 and January 2; 2pm on December 24, 28 to 31 and January 2 and 3; 3pm, December 26 and 27.

As ever, Wendy, Michael and John will be visited in the nursery by Peter Pan, who teaches them to fly with the help of Tinker Bell and takes them on a magical journey to Neverland.

Tickets cost £28 for adults; £17, under 16s and OAPs; £72.80, family ticket for two adults and two children, on sale on 0844 854 2757, at yorkbarbican.co.uk or from the Barbican box office in person.

Charles Hutchinson