FEATURE | THEME PARKS M
ention Florida to anyone outside the state, and an appealing medley of images will come to mind. With its
white sand beaches, orange trees and boats idling down the waterways, Florida is known as the Sunshine State for a reason. But no association has greater sticking power than its theme parks. Playing host to the likes of SeaWorld, Universal
Orlando, Legoland and the titan of them all – Walt Disney World – Florida is the theme park capital of the planet. Seven of the top 10 theme parks in the US are based here, with around 50 million people a year visiting Walt Disney World alone. These resorts are considered a huge engine of tourism and economic growth, as well as occupying a Mecca-like status for millions of children worldwide. Most of the visitors will be too busy making memories to think about what goes on behind the scenes. It’s a once-in-a-lifetime trip for many of them, and far better to enjoy the magic than try to analyse how that magic came together. But it likely wouldn’t surprise them to learn it’s a hugely complex operation. After all, Walt Disney World covers a staggering
43 square miles, making it almost the same size as San Francisco. With more than 170 rides across its four theme parks, along with in excess of 20 shows and attractions, the resort is a true feat of engineering. And nobody knows that better than those in the overhead crane and hoist sector, who are responsible for getting everything (quite literally) off the ground. “Most visitors are unaware of the behind- the-scenes operations that support attractions during both peak and off hours,” explains Jason Ring, vice president of strategy and operations at CraneTech. “These unseen areas include mechanical rooms, brake runs, animation systems, unused props and maintenance bays where ride components are inspected and serviced. Many backstage spaces are confined and difficult for forklifts to navigate, making overhead cranes a safer and more efficient solution.”
How lifting equipment is used in theme parks Clearly, lifting equipment is required at many different stages in the theme park life cycle. The first and most obvious example would be during the construction phase. According to Ring, this is a phase that typically demands highly specialised equipment. “As next-generation rides increase in
complexity, custom-engineered lifting systems are becoming essential,” he says. “Designed to meet ride-specific requirements, end effectors and below-the-hook devices demand rigorous safety, inspection and maintenance programmes.” In terms of lifting systems, one type that is seeing some traction in theme parks is the spider lift. Unlike scissor lifts, which only provide vertical movement, spider lifts can move both horizontally and vertically. This can be useful
Any lapse in safety can result in serious reputational damage to theme park operators.
when manoeuvring across a large, complex structure like a rollercoaster. End effectors are devices attached to the end
of a robotic arm, which perform their designated tasks in the manner of a robotic hand. These are generally used for high-precision tasks, not least automated maintenance, precision rigging in shows and motion simulation in the rides themselves.
Another piece of kit that may come in handy is a mounted or mobile gantry crane. These are often used to relocate large props and animatronic figures, as well as for track installation and seasonal ride teardown. “These systems offer high lifting capacity
and precise movement, making them ideal for removing coaster trains, swapping wheel assemblies or handling large animatronic components across an entire service bay,” says Ring. “They provide greater control and stability than forklifts.” Given the pressures to stay fresh and exciting, theme parks will typically always have some sections under construction. At Walt Disney World, there is an expansion called Tropical Americas coming in 2027, which will feature a new Encanto-themed ride. Meanwhile, the Big Thunder Mountain Railroad is closed for an extensive refurbishment, due to reopen in the spring.
Seaworld Orlando recently opened a new ride called Expedition Odyssey, which will be followed shortly by another major attraction called SEAQuest: Legends of the Deep. And Universal Orlando has gone one better by constructing an entirely new theme park, which opened last year. Known as Epic Universe, it features 11 new rides across five themed worlds. Then, of course, there are the shows, which may include musicals, parades and projection shows. These change with some regularity and
require a lot of lifting work behind the scenes. “In performance and show venues, stage hoists and mobile hoisting systems support lighting, curtains, scenic elements and audio equipment,” says Ring. From a visitor’s perspective, the newest rides and latest spectacles are always going to command the most attention. However, the work for an overhead lifting company doesn’t stop there. Lifting equipment is used just as extensively during the maintenance phase, on rides that may have been up and running for many years. “Maintenance windows at theme parks are
often tight, and – as with most businesses – when critical equipment is down or new machinery is being installed, rides are not operating,” notes Ring. “When they are in operation, they process a high volume of people at high velocities, so there is zero tolerance for engineering and repair error.” As a result, ride operators now apply a
predictive maintenance and repair model to their rides, particularly during peak seasons. The idea is to support safe operations, minimise downtime and reinforce the park’s safety ethos. Predictive maintenance, which typically uses AI-driven systems and real-time monitoring, has also been shown to save up to 20–30% on maintenance costs.
During peak seasons, CraneTech schedules most service work after park hours, to minimise variables, reduce safety risk and keep disruptions at a minimum.
As for the types of equipment used during
maintenance, it varies depending on the application. “Ride vehicles – such as rollercoaster cars, bumper cars and other attraction ‘taxis’ – are heavy and often require overhead lifting equipment to be safely removed from the track and transferred to adjacent service bays for maintenance or upgrades,” comments Ring. “Bridge cranes with wire rope or chain hoists,
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