Metal America: How Are Rollercoasters Fabricated?

Hit the road with AWS and Stephanie Hoffman on KZbin's Metal America series as she visits fabricators across the country and explores some of the industry's most unique careers!
In this episode, Stephanie visits Clermont Steel Fabricators in Batavia, Ohio to discover the exciting world of rollercoaster fabrication.
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Music in this video
"Faster" by Soldier Story (3:51)
"Highway - Instrumental" by Soldier Story (3:08)
"Pedal Down - Instrumental" by Soldier Story (3:43)
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[@AmusementLabs]

For those wondering, the track being made here is for Dr. Diabolical's Cliffhanger, a new Dive Coaster going to Six Flags Fiesta Texas in San Antonio with a 95° drop.

[@benallred5897]

Thank you!

[@rileyroucek2750]

I saw the color scheme and I was like THAT'S DR. DIABOLICAL!!!

[@drdremd]

Sweet!

[@optimistic_shark9569]

yipee i guessed correct

[@marcussheen]

As a roller coaster nerd this video was great. B&M, the manufacturer Clermont are doing the work for is one of the most highly-regarded manufacturers in the world and it's fascinating to see how much work goes into making just a single piece.

[@rockrollangel1972]

there is so much emphasis with kids to go to college but we need people in other fields as well, including this. It looks hard but can be pretty cool to watch the pieces come together.

[@Coastsandcoasters]

Huge respect to the guys working in this. As a newly qualified welder I can’t imagine the hours spent on this! As a theme park fan I appreciate the effort. I thought this was the Nemesis retrack which is my home park coaster of choice for me, but I guess not.

[@johnmelling9950]

These guys are clearly experts at what they do. You can always tell the higher level of quality of a B&M coaster when you look at the track construction.

[@darian.the.barbarian]

Best on earth 🌎

[@printmyridedetroit6115]

AWS posts a video for the welding community, then I check the comments and its loaded with Coaster nerds like myself! :D Great video, thanks for sharing!

[@Coaster101]

Awesome! Probably the best inside look yet at how steel roller coasters are made. Thanks so much for this!

[@JakeCoasters]

One thing I learned from this is that there is no welding on-site when the coaster is being installed. That's probably how they seem to go up so fast once the track arrives, basically just a giant erector set at that point

[@johnmelling9950]

Id imagine they dont want any old Joey with a welder working on their track,

[@TripleTSingt]

it used to be done like that. For example, Colorado Adventure @ Phantasialand (where I work) has both welded and bolted track connectors. Modern track comes in pieces that just get bolted together most of the time.

[@Real28]

This stuff has to be perfect. Lives rely on it. Proud that it's made in my home state. Even though I'm more of a wood coaster fan, B&M stuff is about as high quality as it gets. Just a fan of everything roller coasters. Known about this fab as long as I've been an enthusiast. Always fun to see new track pop up outside their facility before an announcement and the community sorts out what it is and who it belongs to.

[@IxBl4ckH4rtxI]

im proud to be a coaster enthusiast that works there

[@felixcat9318]

What an interesting, informative and educational video this is, well presented and narrated too! I can't imagine anything more challenging to fabricate than these pieces, the multiple demands placed on each piece and the technical and safety requirements make this a very robust yet flexible piece of a huge puzzle. The sense of pride in having had a hand in constructing such a structure must be immense, and quite rightly so. The skills found in this company make thi possible, the machines sre just there to assist the craftspeople doing the work.

[@michaezell4607]

Eagerly awaiting the first shipment of track for KDs 25 wing coaster project.

[@NRGFLOGaming]

I loved this video!!! Seeing them build B&M dive coaster track. I immediately recognized the coaster being built when I saw the paint job. Dr. Diabolical's Cliffhanger at Six Flags Fiesta Texas.

[@OneAdam12Adam]

Made in America. Proud.

[@corybourrier9722]

Kick ass video!!

[@kso808]

Fascinating process!

[@jeradvaughn7527]

Awesome video! I love seeing men/women running beads in good old USA

[@li-qg4vk]

It's just awesome to look at our work from the outside, especially at the old welder with mig mag, I would really like to work in such a production. I welded miles of seams with mig mag in my life, but it's still fucking nice to look at it

[@jbponzi1]

It took years for my company to get Clermont to put in one of our machines. They finally have an MPC with an Infinity Rotator that I am certain is doing a wonderful job for them.

[@Poverty_Welder]

That was awesome! Super well put together video plus that guy had a fun hat. Would probably be a fun place to work if they were hiring!

[@seaflagssixworldfamily463]

Nice! Cliffhanger in the making.

[@repalmore]

5:46 For anyone in the welding industry, THIS is why you should wear a respirator even when welding with MIG. All that crap getting into your lungs can't be a good thing.

[@jeradvaughn7527]

I was surprised to not see some fume extraction. Though this is FCAW process not GMAW. I always were mask when running flux core, mig doesn’t worry me as much

[@SJNFAB]

MOST WELDERS SMOKE WORSE CRAP THEN THE BURNT C02 ARGON HELIUM . I BEEN WELDING SINCE 10YRS OLD. I HOPE I DON'T DIE SOON 😳

[@bamwa]

Oh the guy running the plasma table is even worse off. Where's the giant shop fans?

[@klixtrio7760]

There's a smoke haze in the entire building. That cant be good to breathing every day at work.

[@stephen129]

Really interesting video. Thanks =)

[@drdremd]

This is awesome!

[@j5jackson878]

That leather hat is awesome!

[@ByeDave]

I love that guys golf hat🔥

[@mrdddeeezzzweldor5039]

For clarity, ductile plates are used for the purpose of being flexible enough to handle intermittent stresses and minor deformations from coaster structure movement over the life of the structure without cracking.

[@marcussorenson3380]

I'm surprised that powder coating the coaster track would probably not be faster solution but nevertheless it's great to see they prosses of B&M track being made

[@liamobrien9451]

Man just the bends on that plate must take ages to do, i guess the press brake operator just has to lay out every angle given to him by the engineers, but still, thats so much work

[@jasonfeltus3918]

How do you control distortion on tube column base plates? 👍

[@fm2h3]

I just rode that ride today! Bahahaha

[@ethanthegreat1856]

I'm very satisfied of the video content and experience even just watching, thanks madam.

[@TrainCoasterFan]

13:30 Dr. Diabolical's Cliffhanger! Im a nerd lol

[@michaezell4607]

Ever notice how they can no longer print the actual customer information on the shipping label for each section of track? They now have to use the name X-works instead of the actual park name because of nosey enthusiasts trespassing on Claremont steel property(illegaly might I add) trying to get photographs of the track in order to figure out where each coaster is going.

[@cinderclawz]

The round tube ends on each segement aren't welded in the field?

[@paphattyj]

Yes, they are. The track sections do all bolt together. Then the tubes get welded together on site after they set a few sections of track. They are mostly continuous sections of pipe except at transfer.

[@svenlakemeier]

@@paphattyj No, there is no welding on site. The track connections sometimes get sanded down to smooth out the transition.

[@bamwa]

@@paphattyj I think there is an inner sleeve but no welding.

[@DrCranberry]

@@paphattyj theres literally no welding on site. The tubes seamlessly fit together via a sleeve. Do you know how garbage it'd be to have to cut a rollercoaster apart if you wanted to transport it anywhere?

[@johnmelling9950]

@@DrCranberry Correct but there are no tubes on the inside either. The track is made to be a precision fit when bolted together. No connector tubes are needed,, not on B&M coasters anyway.

[@Whatchamawhozit]

B&M used to be the big dogs on the block but their coaster designs are tame compared to RMC and Intamin... they need to step up their game

[@madhouse5213]

god where's the ventilation

[@justcam504]

my question is… how does payment work? like how in the world does amusement parks make money from this?

[@AlphaKingofGlory]

I need a recommendation of a company which can help me with projects across the world. The systems that I hope to develop need to be developed with reproduction in mind.

[@mouse66]

Look at all the smoke and fumes.

[@michaezell4607]

Calaremont steel was originally known as southern Ohio steel fabricators and once produced Arrow track prior to B&M's entry into the industry in 1990.

[@brunaogoncalves4209]

Are you hiring welders at this company?

[@steveallen6574]

yes

[@brunaogoncalves4209]

@@steveallen6574 Help me

[@blifepartner5315]

Name: Azad Age: 26 Height 5'6" Nationality: Bangladeshi. Experience: 7 years plus. I am engaged in electrical and mechanical plus five filter welding, and industrial generator operator operating. I have been working in Chinese battery factory for seven years with experience. But I was engaged in this work from my childhood and enjoyed working with interest. Are there any job opportunities in European countries at the moment! Please let me know? 🙏🏻 Or is there any training center which takes people from different countries for training. If so please let me know 🙏🏻. I am interested to take up job in a quality good organization and wish to acquire good certificate. So, If there is an opportunity for training in your institute, please let me know, I will be very helpful.

[@tyw4441]

Top secret? How so when its going to be advertised by the park later on 😂

[@Colombiaboy-fr3op]

What’s her name ?

[@OneAdam12Adam]

Thank you to the strong White working class union members that build these amazing machines together.

[@abskates9149]

If You believe in Your Heart That Jesus Died On The Cross And Rose again On The Third Day And Confess With Your Mouth That Jesus Is Lord then you will be saved

[@TheBroz]

lol no