Modern Steel Tracks for Roller Coasters

Group 6:

Charlie Wickham, wickham@iastate.edu

Kishan Patel, patel528@iastate.edu

Mitchell Kiska, mkiska@iastate.edu

Kyle Anetsberger, kaberger@iastate.edu

 Contributions
Charlie: Industry Experience, Sourcing Patents and ASTM Standards

Kishan: Background Research of Manufacturing Methods and Materials

Mitchell: Analysing Advantages and Disadvantages vs Similar Processes

Kyle: Market Analysis, Redesign

Traditional Methods
● Wooden Roller Coasters (1884 - Present)
○ Wooden planks topped with steel plates
○ Constructed on site
○ Large clearance, large tolerances Switchback Railway Texas Stingray
Coney Island 1884 Seaworld San Antonio
Currently Under Construction

● Steel Tube Track (1959 - Present)

○ Bending Pipes in compound curves
○ Welded to steel ties
○ Small Clearance, low tolerances
○ Time consuming, custom, expensive

Matterhorn Bobsleds, West Coast Racers

Disneyland 1959 Six Flags Magic Mountain
Currently Under Construction
Problem
● Research the way modern steel tracks for roller coasters are manufactured

● Compare the modern method of manufacturing tracks to some of the original methods of

manufacture

● Identifying the benefits, and possibly disadvantages, of the modern method, compared to the

original method
Specifications
● The coaster must be made out of raw steel by cutting, bending, and attaching

● Heating of material is to be avoided

● A jig can be made for curved and elongated tracks

Design Loads
F2291 Standard for Design
of Amusement Rides:

● 6G max acceleration
● 1 second duration
● Maximum Force:
6 x Train Weight
Design Loads

Minimum Factor of Safety: 1.2 x 1.2 = 1.44

Materials
● Typically roller coasters use metal or wood to make their tracks and frames. We will be focusing

on the metal tracks, specifically steel rods or pipes

● In addition to the surrounding steel pipe, many coasters are also filled with materials such as

sand or gravel to dampen the noise they produce

● As technology progresses, we might see some different materials be used to make roller coasters

such as: advanced steel and aluminum alloys and high strength fiberglass
Manufacturing Process
Originally, roller coaster tracks have two configurations to support the tracks: One is a thin, trestle

style structure and the other uses thick tube supports. The track is composed of pairs of welded steel

tubes sectioned in place by steel stanchions. Tubular steel coasters are formed by heating and bending

the steel pipes into the desired shape.

New Method (Rocky Mountain Construction)
Laser Cutting Steel Plates

Bending/Assembling

Welding

NDT

Riveting

Sanding, Painting
Plasma cutting
Patent US 9566527: 3. The method of claim 1, wherein the planar material is plate steel having a
thickness in the range of approximately 1/4 inch to approximately 3/8 inch.

● Plasma is a mixture of argon and hydrogen that has

been superheated to become ionized and conductive
● Temperature is typically around 40,000 °F
● Cleaner cut than laser cut
● Requires 400 Volts and DC current
● Much cheaper than laser cutting
Plasma cutting
● Careful planning minimizes waste material

● Programed similarly to CNC machines

● Parts cut nonstop every day

Cut Out Parts

Scrap Material
 Bending / Assembly

1. […] assembling the cut out members, each

without plastic deformation, to form the curve of the
roller coaster track.

4. The method of claim 1, further comprising the

steps of: providing one or more jigs for holding one
or more of the [members] in a given orientation for
permanent assembly.
Attachment Process
● Slight errors in manufacturing can propagate over thousands of feet of track

● Design features allow every connection to accommodate some error in assembly

a. Direct from CAD toolpath generation minimizes error

b. Slotted holes with rectangular washers allow adjustable connection with the structure
c. Bolts locate and compress connecting profiles ensuring alignment
d. Running surfaces pass over seams, connecting with diagonal gaps
Pros
● No permanent bending, heating, or other plastic deformations resulting in less fatigue and more

strength

○ Much larger and more efficient roller coasters can be made

○ Longer lifespan

● I-Beam like structure much stronger than pipe

● Simplicity of manufacturing process leads to cheaper and faster manufacturing

● Scrap material easily reused

● Product much less vulnerable to deformation and cracking compared deformed steel pipes
Cons
● Although theoretically quieter, there is no sound dampening method available

● Load not distributed as evenly as steel pipe

● Process heavily involves welding, making good welds a priority

● End product more rigid

● Much more expensive material cost than wooden coasters

Cost
● A-36 steel costs about $327.35 per beam (about ¼ in thick, 12 in X 18 in X 25 feet)

● Scrap metal is stored and reused to save on costs

● Wooden coasters cost about $67.13 for the same sized beam

● Due to increased safety of track, less injuries will occur and liability money will be saved

(previously $1 million in liability insurance)

Redesign #1
● Beams can have tabs that are bent (like in a file cabinet)

● Once bent, bolted together

● No welding, less material

● Bolting is simpler, much cheaper, and can make servicing sections of the coaster

significantly easier
Redesign #2
● Extrude Molten Steel

● No Assembly required

● Save money on welding

● Quicky produce segments without manual jigs

Redesign #3
● “I - beam” tracks

● No hollow center, faster to produce than pipe bending

● Can be computer automated

 Poor Benchmark Excellent

Decision Matrix * ** *** **** *****

Low Cost Low Manufacturing Time Long Service Life Smooth Rider Experience

Traditional Wood
***** ***** ***** *
Traditional Steel Pipes
* * *** *****
New I-Box
*** *** *** ***
Bolted Tabs **** **** **** ***
Extruded Profile *** ***** ** ****
I-Beam Roller **** ***** ** *****
 References
[1] Schilke, A., Grubb, F., Bachtar, D, inventor; Rocky Mountain Coasters Inc., assignee. Rolling Vehicle Track U.S. patent
US9,566,527 B2, 2013.
[2] Schilke, A., Grubb, F., Bachtar, D, inventor; Rocky Mountain Coasters Inc., assignee. Rolling Vehicle Track U.S. patent
US8,590,455 B2, 2013.
[3] ASTM Standard F2291, 2019, "Standard Practice for Design of Amusement Rides and Devices," ASTM International, West
Conshohocken, PA, 2003, DOI: 10.1520/F2291-19E01, http://www.astm.org/cgi-bin/resolver.cgi?F2291
[4] CoasterForce. “Rocky Mountain Construction Factory Tour part1 of 5 - CEO Fred Grubb Interview” Parts 1 through 5. YouTube,
Interview of Fred Grubb, 2 Nov. 2015, https://www.youtube.com/watch?v=zXQ_jzcpCIM
[5] https://www.azom.com/article.aspx?ArticleID=11958
[6] https://www.midweststeelsupply.com/store/a36steelplate
[7] https://www.ingentaconnect.com/content/ince/ncej/2011/00000059/00000004/art00003
[8] https://www.lincolnelectric.com/en-us/equipment/plasma-cutters/process-and-theory/Pages/how-a-plasma-cutter-works.aspx
[9] https://www.homedepot.com/b/Lumber-Composites-Boards-Planks-Panels-Appearance-Boards-Planks
[10] https://www.insurancejournal.com/news/southcentral/2013/07/24/299530.htm
Questions?