Behind-the-Scenes: Seasonal Ride Maintenance at Carowinds

Even though Carowinds may be closed for the season, the park remains a hub of activity. Our dedicated associates are hard at work, diligently preparing for the opening of the 2024 season on March 9, 2024. A pivotal part of these preparations revolves around Carowinds' maintenance team, which plays a crucial role in ensuring the safety of the park's rides and attractions through meticulous seasonal maintenance procedures.

"Annual maintenance is extremely important for any type of machinery, from cars and airplanes to our thrilling rides," said Steve Jackson, Carowinds' director of Maintenance and Construction. "We maintain our equipment to be reliable, safe, and fun for our guests."

At Carowinds, the safety of our associates and guests remains our top priority. Ensuring that our rides are well-maintained and cared for is just one of the ways we demonstrate this commitment.

Train Removal

Once Carowinds closes its gates for the season, our experienced crews immediately swing into action, carefully removing trains or cars from each ride and attraction. This process may involve the use of cranes, forklifts, and various other specialized machinery.

For roller coasters, the trains are moved back into their typical storage track or train house. Trains are removed one car at a time, starting with the back of the train. Each car is carefully lowered to the ground using a hoist or winch. After removal, the cars and trains are transported to Carowinds' maintenance shop at the back of the park.

Inspection and Testing

After the cars and trains arrive at the maintenance shop, our ride technicians commence a thorough inspection and testing process.

First, trains are organized and assigned to pallets, while small pieces are arranged in containers. Next, each train is completely disassembled, allowing for detailed inspection of each piece, all the way down to the most miniature screws and bolts.

"Disassembly is a very methodical process. We take the train bodies, lap bars, brake fins, wheels, and wheel bearings off the chassis," Jackson said.

After disassembly, each piece of the train is subject to extensive nondestructive testing, completed in Carowinds' on-site welding shop. Different methods of nondestructive testing are used depending on the type of ride and train piece being examined. These protocols include X-ray, magnetic particle testing, x-ray, ultrasonic, and accelerometer testing.

Many of the rides and attractions at Carowinds are designed and built by some of the best ride manufacturers worldwide, including companies like Bolliger & Mabillard, Vekoma, and Mack Rides. Parts from each ride are tested according to these manufacturers' standards and elevated industry standards.

This meticulous annual process extends the operational life of each attraction while ensuring that rides continue to operate smoothly, upholding the highest safety standards for our valued guests.

Refurbishment

The off-season provides an ideal window for Carowinds' maintenance team to assess the appearance of each ride and identify those due for routine enhancements. These improvements include fresh track paint, new train and car finishes, signage, and queue line updates.

For instance, The Flying Cobras' trains are receiving a fresh coat of paint to revitalize the coaster's theming this winter. Additionally, a selection of hand-carved horses from The Grand Carousel undergoes repainting each year to ensure the historical attraction maintains its pristine appearance.

"We have talented people who care a lot about what they do. Our team is creating some amazing, themed products. The trains look awesome when they come out of the shop," said Jackson.

Train Storage

Following the necessary inspections, testing, and required refurbishments, cars, and trains are reassembled and securely stored within Carowinds' maintenance area for the remainder of the off-season. This safeguards them from the elements while not in use.

As the time approaches for trains to return to their respective rides, Carowinds' operations team initiates their series of safety inspections and tests in preparation for the park's grand reopening.

At Carowinds, we are committed to providing a safe and thrilling experience for all our guests. We'll share more information about what's happening behind the scenes as we prepare for a fun-filled 2024 operating season.