WDW History

The Walt Disney World Monorail Runs on Beams Filled With Styrofoam

From WDW History, the Walt Disney World history archive

How the WDW Monorail's concrete-and-foam beams were built, why the fleet is still all one generation more than three decades on, and the 2009 crash that took two colors off the roster for good.

Opened: October 1, 1971, with Walt Disney World. Type: elevated rubber-tired transit system, adapted from a Disneyland attraction into an actual transportation network. Status: operating, across three connected loops. Fleet: currently twelve Mark VI trains, with no successor generation yet announced.

The beam the monorail actually rides on is the part almost nobody thinks about, and it’s the strangest piece of the whole system. Each concrete guideway section was cast around a polystyrene foam core by Concrete Technology Corporation in Tacoma, Washington, then shipped roughly 3,400 miles by rail to Florida before Walt Disney World had even opened. Some 337 of those sections, each 26 inches wide, 100 to 110 feet long, and weighing up to 60 tons, now sit on pylons running over trees, swamp, and parking lots, and in one stretch, straight through the middle of the Contemporary Resort’s atrium.

Built to move people, not just entertain them

Disneyland’s monorail had been a ride: point A to point A, scenery in between. Walt Disney World’s version was the first time Disney built one as actual infrastructure, meant to get guests from a parking lot to a park gate and back, on a schedule, at volume. Martin Marietta built the original fleet, ten low-nosed Mark IV trains with a profile monorail fans still nickname the “Lear jet” look, running on two loops laid around Bay Lake for opening day: a Resort loop stopping at the Contemporary, the Polynesian, and the Ticket and Transportation Center on the way to Magic Kingdom, and an Express loop skipping the resorts to run the TTC-to-park route nonstop.

Two more trains, Lime and Coral, joined the fleet in 1984, built in-house by Walt Disney Imagineering rather than Martin Marietta, to help absorb the crowds Epcot had brought to the system two years earlier. Instead of a solid color band, each carried a delta symbol across two of its doors, white on Coral and dark blue on Lime, an homage to original cast costume colors and a way to keep the new Lime from reading as the existing Green train and the new Coral from reading as the existing Pink train. When the Mark IVs aged out of service in the early 1990s, most were scrapped, with parts recycled into the incoming Mark VI fleet; only Coral and Lime survived intact, sold to Las Vegas for a reported $3.5 million each to run first on the MGM Grand/Bally’s monorail and later the Las Vegas Monorail.

A resort loop that grew, and resorts that never got built

The Resort loop ran with four stops from opening day: the TTC, the Contemporary, the Polynesian, and Magic Kingdom. When the Grand Floridian opened in 1988, its monorail platform was built into that existing loop between the Polynesian and Magic Kingdom, becoming its fifth stop. Disney’s early planning had also sketched several themed resorts around the property that never got past the concept stage, an Asian resort, a Persian resort, a Venetian resort, and a Mediterranean resort among them, most shelved once the 1973 oil crisis curbed Disney’s expansion plans (the Mediterranean site had its own problem, too: bad soil).

The Epcot line came later and separately. It opened June 1, 1982, running from the TTC out to Epcot’s front gate on its own dedicated track, connected to the resort loops only by a junction near the TTC that lets a train switch systems when Disney needs to reposition it. At a commonly cited cost of roughly a million dollars a mile in 1982, it was also the last major expansion the monorail system ever got. There’s also a maintenance spur behind Fantasyland, connecting the Express loop back to the Resort loop, that was reportedly built with the shelved Persian Resort in mind; today it only moves trains to and from the shop and isn’t part of any passenger route.

The fleet running today, and the crash that shrank the color roster

The Mark VI fleet, built by Bombardier, replaced the Mark IVs starting in 1989 with Monorail Blue and finished the rollout in 1993 with Monorail Coral. Disney hasn’t introduced a successor generation since: as of mid-2026, all twelve trains on property are still Mark VI, now more than three decades old, and rumors of a replacement fleet that have circulated since at least 2018 haven’t materialized.

Disney runs a color-coded roster rather than named trains, and the current list, Black, Blue, Coral, Gold, Green, Lime, Orange, Peach, Red, Silver, Teal, and Yellow, is shorter than the system’s full history. Purple was retired after a fatal collision at the Ticket and Transportation Center on July 5, 2009, when Monorail Pink, backing up during a failed track switch, struck the stationary Monorail Purple; Purple’s pilot died, and Disney added new safety procedures afterward, including a mandatory second crew member to spot any reverse movement. Pink didn’t survive that crash either. It was the train that struck Purple, and both were permanently retired together rather than repaired and returned to service; Monorail Peach, introduced in 2011, was built using surviving cars from the two retired trains.

Little-known fact: the monorail shop’s paint booth sits about 25 feet off the ground on its own wall-mounted lift, letting painters work around a full-size train without scaffolding, and a complete repaint takes three to six weeks depending on the job.

Why the loop layout still matters if you’re booking a room

None of this history changes how the system works today, but the loop structure is worth knowing before you pick a hotel. Only three resorts sit directly on the Resort loop, the Contemporary, the Polynesian, and the Grand Floridian, which is the whole reason those three carry a price premium over comparable rooms a five-minute drive away. Everywhere else on property means a bus, boat, or Skyliner ride to the parks instead. If you’re still working out which resort tier actually buys you monorail access and which doesn’t, a rundown built for first-time visitors walks through what each category gets you.

The Epcot line matters for a different reason: it’s the fastest way between the TTC and Epcot’s front gate, and a day that starts at Magic Kingdom can end at Epcot without ever leaving the monorail system, as long as you route it through the TTC junction. Mapping that kind of connection ahead of time, rather than discovering it mid-trip, is exactly what a day-by-day itinerary planner is built to handle.

Two generations of train in more than fifty years, a handful of resorts that never got their own stop, and a paint booth suspended 25 feet in the air: the Walt Disney World Monorail is still doing the same basic job it started with in 1971, moving people from a parking lot to a castle without a single stoplight along the way.