Behind-the-Scenes: Ride Inspections at Carowinds
Before our guests walk through our gates, Carowinds maintenance teams work hard every day to thoroughly inspect and test the park's rides and attractions. These daily safety inspections are integral to our commitment to providing our guests with a secure and fun experience.
Final Maintenance Procedures
After seasonal maintenance is completed, Carowinds maintenance associates meticulously return the ride vehicle to its respective attraction. The installation process for ride vehicles is the exact reverse of the removal process.
After reinstalling ride vehicles, our teams conduct a final visual inspection of each ride's structure. For wooden coasters, trained associates walk the track inspecting every element. Tall rides require lifts for thorough inspections.
Carowinds also uses camera-equipped drones on select attractions to enhance our inspection capabilities, making the process faster and more efficient than traditional methods.
Pre-Opening Checklist
Once our maintenance crew concludes their inspections, the operations team provides a comprehensive pre-opening checklist for each attraction. This checklist must be completed for each attraction before ride testing begins.
The checklist includes testing restraint systems, ensuring safety devices, such as fire extinguishers and safety signage, are present, and securing lock-out zones. Any area where track and ride units are less than 10 feet above the ground is considered a lock-out zone. While completing the pre-opening checklist, ride operators ensure the gates to that zone are locked and inaccessible to guests or associates during operation.
Our rides and attractions are inspected daily by our staff during operation. The rides also undergo regular weekly, monthly, and annual inspections according to the manufacturer's guidelines. Our rides maintenance staff thoroughly inspects each ride at these intervals, checking numerous elements. Depending on the ride, these range from inspecting restraint systems and ride structures to ride control and drive systems. Our mechanics and electricians cycle the ride empty each morning to ensure the ride and its systems function correctly. Rides staff also conduct daily operational tests before opening, including running a cycle with a test rider onboard.
This checklist is crucial for the season's opening and is completed daily to ensure ongoing safety.
Commissioning
After completing the pre-opening checklist for an attraction, operations associates commission each ride.
Commissioning refers to operating a ride for a set number of cycles without riders present. Some attractions complete up to 500 full cycles, with crews performing tests and inspections to ensure the ride's integrity throughout that period.
Cycles are conducted as they would be under normal operations, including opening and closing automatic gates, buckling and unbuckling seatbelts, and securing and releasing restraints. This process is completed when a ride reopens after an extended closure (including seasonal closures), receives new parts, or undergoes rehab maintenance, or when a new ride is installed at the park.
"During the commissioning process, we're ensuring that all aspects of the attraction are operating correctly," said Steve Motzkus, ride operations manager at Carowinds.
The required number of cycles varies by attraction and depends on the reason the attraction is being commissioned. Each process step is carefully monitored, with remedial action to ensure the structure's safety and integrity. Upon completion of this phase, the ride will undergo final inspections.
State Inspections
Before opening, Carowinds' rides undergo state inspections by either the North Carolina Department of Labor's Elevator and Amusement Device Bureau (the Bureau) or the South Carolina-appointed third-party agency, depending on the ride's location. These inspections ensure structural integrity and compliance with safety standards.
"Copperhead Strike's station is in South Carolina, so that attraction is inspected by South Carolina even though some portions of the track cross over into North Carolina," said Motzkus.
State inspectors examine the structural components of each ride to ensure their integrity. Inspections are typically scheduled during commissioning, allowing representatives to observe operating procedures—inspection of the entire track, support columns, and foundation. Inspectors also ensure that all safety signage required by law and the ride manufacturer is present and visible. Additionally, ride operators may be asked to demonstrate ride evacuation procedures.
The return to operation marks the end of a comprehensive plan dedicated to ensuring the coaster's safety and operational readiness. After completing these inspections, rides are awarded a license, allowing them to open for guests.
"This entire process, along with our daily checks, is designed for the safety of our guests and associates, as that is our number one priority," said Motzkus.
