Tearing across the Alhambra stage at up to 40mph, the cast of Starlight Express look pretty comfortable performing on wheels.

But it took a few weeks of intensive training for these high-energy performers not just to learn to skate, but also perform tricky dance moves and acrobatics on roller boots.

“They start off as dancers/ singers/actors and go to skate school,” says dance legend Arlene Phillips, director and choreographer of this new production of the smash-hit musical, currently on in Bradford. “When I first started I said, ‘Everything that can be done on two feet can be done on skates’ but I learned it’s a whole different way of moving. You have to allow the skates to lead you.

“A lot of dance crews do hip-hop on skates, but here everyone wears a big costume and plays a character too. Wearing skates changes the dancers’ posture and breathing, and the way they move. Some costumes are very heavy and add height and width. You need a lot of stamina to do any show, but particularly this one!”

With every movement timed to the music, lights and pyrotechnics, the cast can’t put a foot wrong. And, as happened during the show’s last visit to Bradford, when the actress playing pretty rail carriage Pearl injured her leg during the first act and was taken to Bradford Royal Infirmary, the breakneck speeds can be tricky.

“There’s always a bit of a drama,” smiles Arlene, who was the show’s original choreographer in 1984.

“They make it look effortless, but of course there’s danger involved. Skating injuries don’t happen very often, but when they do it’s a reminder of what a thrilling show this is.”

Despite its unlikely premise – rival toy steam, diesel and electric engines competing in a dramatic race, performed entirely on roller-skates – Starlight Express has become one of the world’s longest-running musicals. “It’s a great show for children of all ages,” says Arlene. “The score is varied, from country to rap, and the dance has to fit that. Dads and sons love the athletic stunts and little girls love the glamour and spectacle.”

As a young dancer, Arlene got her break when film director Ridley Scott asked her to choreograph an ice-cream commercial. She went on to create raunchy Eighties dance troupe Hot Gossip.

She has worked with such stars as Elton John, Diana Ross, Tina Turner, Robbie Williams, Aretha Franklin and Duran Duran, and has choreographed countless hit shows including Saturday Night Fever, We Will Rock You and Andrew Lloyd Webber’s West End revivals of The Sound Of Music and The Wizard Of Oz. Her film choreography includes Annie, Highlander and Monty Python’s Meaning of Life.

When we chat, she has just choreographed Englebert Humperdinck’s performance on this year’s Eurovision Song Contest.

“I’m using one of the girls from So You Think You Can Dance. It’s great watching their careers grow,” she says.

The BBC1 show is one of several Arlene has been involved in, with others including DanceX and Strictly Come Dancing. “It’s great that dance shows are inspiring young people to take it up. Dance engages the mind and body, it’s good for fitness, discipline, motivation and co-ordination, but not everyone makes it. Most don’t,” she says. “Unless you have real talent and are prepared for the tough life of a dancer, keep it as a hobby.”

* Starlight Express runs at the Alhambra until Saturday, June 16. For tickets, ring (01274) 432000.