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This comment piece was written by Sabuj Mallik, Head of School of Engineering and the Built Environment at BNU. 

Theme parks are designed to provide thrill and excitement, but behind every ride, particularly rollercoasters, lies an intricate framework of engineering precision and rigorous safety measures. While the public often focuses on the fear factor of these towering structures, the reality is that theme park infrastructure is built with some of the most stringent safety standards in the engineering world.

The Engineering of Rollercoasters

Building a rollercoaster is a feat of advanced engineering, requiring a careful balance between physics, materials science, and human psychology. Engineers must calculate forces such as acceleration, deceleration, and g-forces to ensure that riders experience a thrilling yet safe ride. The track layout, support structures, and braking systems must be meticulously designed to prevent mechanical failure and ensure smooth operation. Furthermore, rollercoasters undergo computer simulations and real-world stress tests before they ever accommodate a single rider.

Rollercoaster design integrates structural, mechanical, and electrical engineering, ensuring each ride meets rigorous safety standards. The core elements of all rollercoasters include a car, a track, and a braking system. Tracks can be made of wood or steel, each offering distinct design and maintenance requirements.

Wooden vs Steel Rollercoasters: Does Material Affect Safety?

Wooden coasters use massive wooden trestle-style structures to support the track above the ground. These structures are typically made from Douglas fir or southern yellow pine, treated to prevent deterioration. The wooden components are supported by concrete foundations and connected with bolts, nails, and reinforced steel plates. Due to the nature of wood, these coasters require more frequent inspections to account for natural expansion, contraction, and wear over time. A prime example is the American Eagle at Six Flags in Gurnee, Illinois, which features 1.6 million feet of wood and over 60,000 bolts.

Steel rollercoasters, in contrast, utilize precision-engineered tracks constructed from welded steel tubes. These structures allow for smoother rides, advanced track layouts like loops and corkscrews, and lower maintenance demands. The Pepsi Max Big One at Blackpool Pleasure Beach in England is an engineering marvel, requiring 2,215 tons of steel and 60,000 bolts. Despite differences in material, both wooden and steel coasters incorporate steel track rails, steel axles, and braking systems that ensure reliable operation.

Safety Testing: A Rigorous Process

Every rollercoaster undergoes extensive safety testing before it opens to the public. Engineers build computer simulations and working prototypes to assess every design aspect. Before human riders are allowed on board, coasters are loaded with test dummies filled with water to simulate real passengers. Accelerometers measure g-forces throughout the ride, ensuring they remain within safe limits, typically not exceeding 3.5 g in most U.S. rides.

Beyond initial testing, amusement parks implement daily, weekly, monthly, and annual inspections. Engineers inspect structural components, seat restraints, emergency brakes, and control systems to ensure all safety mechanisms function correctly. Advanced non-destructive testing methods help detect any material defects or wear.

In the UK, all rides must pass rigorous safety checks under the Amusement Device Inspection Procedures Scheme (ADIPS). Before a ride opens, it undergoes design reviews, material testing, and mechanical inspections. At parks like Thorpe Park and Alton Towers, daily maintenance routines involve hours of pre-opening preparation, while annual inspections involve independent engineers dedicating thousands of hours to verifying ride safety.

The Science of Thrills and Safety

Rollercoasters operate on principles of kinetic and potential energy, carefully manipulated to provide an exciting yet controlled experience. Engineers balance thrilling g-forces with safety limits to ensure riders experience excitement without excessive physical strain. The first incline is calculated to provide enough potential energy for the train to complete the ride, while friction and air resistance are accounted for in the final design.

All coasters feature braking systems designed to safely stop the ride. These include long fins that pass through pinch brakes or advanced magnetic braking systems, which use magnetic force to slow the train smoothly. Safety systems are also integrated into the ride’s control mechanisms, automatically stopping the ride in case of any unexpected obstructions or adverse weather conditions.

Public Perception, Statistics, and Fear

Despite these rigorous safety measures, public fear of rollercoasters and theme park accidents persists. High-profile incidents, such as the recent shut down announcement of Oakwood Theme Park, Wales’ largest theme park,  following a serious safety concern (), contribute to this anxiety. However, according to the International Association of Amusement Parks and Attractions (IAAPA), the likelihood of being seriously injured on a theme park ride in the U.S. is 1 in 24 million. In the UK, only one person has died on a modern steel rollercoaster since 2004. Most amusement park incidents are linked to falls or pre-existing health conditions rather than ride malfunctions.

Theme parks must work not only to enhance safety but also to communicate these extensive precautions to the public. Transparency about safety protocols, the science behind ride engineering, and routine maintenance practices can help alleviate fear and restore public confidence in these attractions.

Conclusion

Theme Park rides are marvels of modern engineering, balancing exhilaration with rigorous safety standards. Whether built from wood or steel, every ride undergoes meticulous design and testing processes before welcoming riders. However, overcoming public fear requires more than engineering excellence—it demands effective communication and reassurance about the hidden safety measures that make these experiences possible. As the theme park industry evolves, so too must its approach to public trust, ensuring that fear does not overshadow the thrill of innovation.