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How Are Roller Coasters Built?

As humans, we have some rather strange pastimes. From sports and cinema to bungee jumping and rock climbing, there are a million different ways to find pleasure and satiate our appetites for excitement. With that said, among the most popular and accessible forms of adrenaline-based activities are roller coasters. Since their invention over 150 years ago, these knee-trembling contraptions have birthed an entire industry; enthusiasts travel the globe in hopes of riding some of the biggest and best that amusement parks have to offer.

Thanks to years of careful engineering and development, roller coasters have surpassed their original creators’ wildest dreams, with many towering hundreds of feet above the ground and reaching well over 100mph.

Here at Staffordshire Fabrications, we have a wealth of experience delivering high-quality products and technical guidance to the theme park sector.

Read on to discover how these thrilling inventions are built.

Key Factors

Before a roller coaster is constructed, there are a number of considerations that must be taken into account. Factors such as the age, height and weight of intended riders must be kept in mind throughout the design and manufacturing process.

Every aspect of the roller coaster must be properly considered before construction can begin. From materials and cart types to track layouts and speed, there are endless variables, with a multitude of combinations leading to truly unique ride styles.

Launch Systems & Brakes

Of course, one of the most important elements of any roller coaster is the means with which it is propelled. Engineers and manufacturers must decide which launch mechanism will be the most effective for the cart and track combination in question; chain lifts and catapult launch systems are the most common means of cart propulsion.

As is the case with any kinetic mechanism, a means of stopping safely and effectively is essential. Modern roller coasters feature cleverly designed braking systems. Typically, a cart will have two ways to stop, one which slows the cart each time it is used and another that brings it to an extreme halt in the case of an emergency.


It goes without saying that the top priority when constructing roller coasters is safety. Before rides are built and opened to thrill-seekers, they are rigorously tested using computer simulations. Once built, rides of all sizes undergo thorough testing in a range of conditions to ensure they are safe to use at all times.

Staffordshire Fabrications: Serving The Theme Park Sector

When it comes to the materials used to construct such coasters, it is imperative that they meet the highest quality standards. Here at Staffordshire Fabrications, we’re proud to have established a reputation for excellence in the delivery of fabrications and technical guidance. As a market-leading metal fabrication service, we can create bespoke solutions to meet every one of your requirements.

To discuss our range of services with a member of our experienced team, get in touch today.