AS 3533.4.

3—2007
AS 3533.4.3—2007

Australian Standard®

Amusement rides and devices

Part 4.3: Specific requirements—Roller

coasters
This Australian Standard® was prepared by Committee ME-051, Amusement Rides and
Devices. It was approved on behalf of the Council of Standards Australia on
11 December 2006.
This Standard was published on 30 January 2007.

The following are represented on Committee ME-051:

• Australian Amusement Association

• Australian Amusement Leisure and Recreation Association
• Australian Chamber of Commerce and Industry
• Australian Industry Group
• Australian Ski Areas Association
• Consumers Federation of Australia
• Department for Administrative and Information Services, S.A.
• Department of Industrial Relations, Qld
• Department of Labour, New Zealand
• Engineers Australia
• Ministry of Economic Development, New Zealand
• Safety Institute of Australia
• Showmen’s Guild of Australasia
• Victorian Showmen’s Guild
• Victorian WorkCover Authority
• WorkCover New South Wales
• Worksafe Western Australia

This Standard was issued in draft form for comment as DR 06288.

Standards Australia wishes to acknowledge the participation of the expert individuals that
contributed to the development of this Standard through their representation on the
Committee and through public comment period.

Keeping Standards up-

up-to-
to- date
Australian Standards® are living documents that reflect progress in science, technology and
systems. To maintain their currency, all Standards are periodically reviewed, and new editions
are published. Between editions, amendments may be issued.

Standards may also be withdrawn. It is important that readers assure themselves they are
using a current Standard, which should include any amendments that may have been
published since the Standard was published.

Detailed information about Australian Standards, drafts, amendments and new projects can
be found by visiting www.standards.org.au

Standards Australia welcomes suggestions for improvements, and encourages readers to

notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at
mail@standards.org.au,
mail@standards.org.au or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.
 AS 3533.4.3—2007

Australian Standard®

Amusement rides and devices

Part 4.3: Specific requirements—Roller

coasters

First published as AS 3533.4.3—2007.

COPYRIGHT
© Standards Australia
All rights are reserved. No part of this work may be reproduced or copied in any form or by
any means, electronic or mechanical, including photocopying, without the written
permission of the publisher.
Published by Standards Australia GPO Box 476, Sydney, NSW 2001, Australia
ISBN 0 7337 7987 5
AS 3533.4.3—2007 2

PREFACE
This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee, ME-051, Amusement Rides and Devices, to complement the general
requirements for amusement rides and devices given in AS 3533.1, AS 3533.2 and
AS 3533.3.
This Standard was prepared by the Australian members of the Joint Standards
Australia/Standards New Zealand Committee ME-051. After consultation with stakeholders
in both countries, Standards Australia and Standards New Zealand decided to develop this
Standard as an Australian Standard rather than an Australian/New Zealand Standard.
The objective of this Standard is to provide designers, manufacturers, proprietors and
operating staff with requirements and guidance specific to the design, construction,
operation and maintenance of roller coasters that will protect the health and safety of both
operating staff and patrons.
The Standard is part of a series designed to cover aspects of safety for amusement rides and
devices. Parts 1 and 2 deal with the general aspects of safety common to all kinds of
amusement rides and devices and are intended to be used in conjunction with the specific
requirements for the particular type of ride. While some ride-specific requirements have
been included in Parts 1 and 2, these are now being progressively moved into individual
Standards in a new AS 3533.4 series. Parts in the AS 3533.4 series relate to particular rides
or devices and give requirements and guidance tailored to the particular kinds of hazards
relevant for that ride or device.
It should be noted that compliance with this Standard alone does not necessarily ensure that
all legal obligations are being fulfilled.
The term ‘informative’ has been used in this Standard to define the application of the
appendix to which it applies. An ‘informative’ appendix is only for information and
guidance.
 3 AS 3533.4.3—2007

CONTENTS

Page

FOREWORD.............................................................................................................................. 4
1 SCOPE........................................................................................................................ 5
2 APPLICATION .......................................................................................................... 5
3 REFERENCED DOCUMENTS.................................................................................. 5
4 DEFINITIONS............................................................................................................ 6
5 DESIGN AND CONSTRUCTION ............................................................................. 6
6 OPERATION AND MAINTENANCE ..................................................................... 11

APPENDIX A HIGH ACCELERATION AREAS AND INVERTED ELEMENTS......... 19

AS 3533.4.3—2007 4

FOREWORD
At present various persons have been assigned a duty of care in the general occupational
health and safety legislation in Australia. While the legislation is slightly different in each
State, in general these duties can be interpreted as indicated in this Foreword and may
provide an understanding of the basis for the requirements in this Standard.
Under legislation, employers (including the operator of a roller coaster) have a duty to
ensure the safety of their employees and other people at the workplace. The operator of a
roller coaster has a duty to ensure that participants and others present are not exposed to
risks arising from the activities at the workplace. This duty includes conducting a risk
assessment of the ride and its operation to consider foreseeable risks to employees,
participants and others, and to implement measures to eliminate or control such risks.
Designers, manufacturers and suppliers of the roller coaster also have duties to ensure the
plant and equipment is safe and without risk when used properly. Additionally they need to
provide information that is necessary to enable the plant to be used properly.
 5 AS 3533.4.3—2007

STANDARDS AUSTRALIA

Australian Standard
Amusement rides and devices

Part 4.3: Specific requirements—Roller coasters

1 SCOPE
This Standard sets out requirements and guidance for the design, construction, operation
and maintenance of roller coasters.
NOTE: This Standard refers to roller coasters whose main characteristic is that the motion of the
vehicle is produced mainly by an exchange between potential and kinetic energy, and where an
initial store of potential energy is provided by an elevating, launch or self-driven system.
Coasters falling into this category may employ trains of interconnected vehicles, an individual
vehicle or a number of individual vehicles, and may incorporate features in their track design
which cause inversions (loops) and high accelerations. They may travel in both forward and
reverse directions.

2 APPLICATION
This Standard should be used in conjunction with AS 3533.1, AS 3533.2 and AS 3533.3,
which provide requirements and recommendations on matters common to all amusement
rides and devices. Specific requirements in this Standard take precedence over
corresponding requirements in AS 3533.1, AS 3533.2 and AS 3533.3. If the requirements of
any part of this Standard conflict with any National, State or Territory regulations, the
appropriate statutory regulations shall apply.

3 REFERENCED DOCUMENTS
The following Standards are referred to in this Standard:
AS
1720 Timber structures
1720.1 Part 1: Design methods
3533 Amusement rides and devices
3533.1 Part 1: Design and construction
3533.2 Part 2: Operation and maintenance
3533.3 Part 3: In-service inspection
3978 Non-destructive testing—Visual inspection of metal products and components
4024 Safeguarding of machinery
4024.1 Part 1: General principles (series)
60204 Safety of machinery—Electrical equipment of machines
60204.1 Part 1: General requirements (IEC 60204-1, Ed.5 (FDIS) MOD)
61508 Functional safety of electrical/electronic/programmable electronic safety-related
systems
61508.1 Part 1: General requirements
AS/NZS
1554 Structural steel welding
1554.1 Part 1: Welding of steel structures

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AS 3533.4.3—2007 6

AS/NZS
1554.5 Part 5: Welding of steel structures subject to high levels of fatigue loading
3000 Electrical installations (known as the Australian/New Zealand Wiring Rules)

4 DEFINITIONS
For the purpose of this Standard, the definitions below apply.
4.1 Competent person
A person who has acquired through training, qualifications or experience, or a combination
of these, the knowledge and skills enabling that person to perform a specified task.
4.2 Risk assessment
The overall process of hazard identification, risk analysis and risk evaluation.
4.3 Risk management
The systematic application of management policies, procedures and practices to the tasks of
identifying, assessing, eliminating, controlling and monitoring risk.
4.4 Roller coaster
A device where patrons are transported in wheeled vehicles continuously in contact with
and along a fixed rail system permitting, in part or in whole, the motion to be the result of
the acceleration due to gravity.

5 DESIGN AND CONSTRUCTION

5.1 General
Where characteristics of the motion conferred on vehicles and patrons create hazards not
anticipated in this Standard, designers shall eliminate the hazards or apply appropriate risk
control measures.
5.2 Vehicles
Vehicles for roller coasters shall comply with the following:
(a) Any vehicle used on a given roller coaster shall be specifically designed and matched
to the track and its configuration as installed.
(b) Adequate padding shall be provided where the action of the device can cause patrons
to be thrown upon or against any part of the vehicle.
(c) The interior and exterior parts of vehicles with which patrons can come in contact
shall be smooth and rounded, free from sharp, rough or splintered edges and corners,
and have no protruding studs, bolts, screws or other projections with the potential to
cause injury.
(d) No part of any vehicle in the train shall move sufficiently to come into unintended
contact with any part of the track or any ancillary structure associated with the track.
(e) Where vehicles are operated as trains, any interconnection shall incorporate a safety
connection or other redundant or secondary device such that in the case of failure of
the primary connection—
(i) the vehicles shall not separate or come together beyond a safe margin;
(ii) there shall be no impairment to the function of braking or anti-roll-back
systems;

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 7 AS 3533.4.3—2007

(iii) no portion of the interconnection assembly shall become dislodged to the extent
that it can fall from the train or interfere with the track or any ancillary
structure in any way as to cause an additional hazard;
(iv) the train shall maintain steerage sufficient to negotiate any feature of the track;
and
(v) the failure shall be readily observable or a means shall be in place to positively
detect and signal that failure.
(f) Safety ropes and similar devices shall not carry operational loading in normal
circumstances and shall be configured to minimize wear and optimize ease of regular
inspection.
(g) Interlocking restraints shall comply with the requirements for such restraints in
AS 3533.1 and shall be designed to achieve a factor of safety (ultimate failure of any
component) of not less than 10, or shall incorporate redundant features providing
equivalent safety which, upon coming into action, immediately flag or indicate that
occurrence in a readily identifiable manner.
(h) Where restraints against ejection are not required, devices (such as lap bars or
similar) to retain patrons generally in their proper riding position shall be provided,
and shall comply with the requirements for non-interlocking restraints in AS 3533.1.
(i) Vehicles shall be equipped with devices for the prevention of derailment and lift-off.
Safety devices against lift-off (rollers or claws) shall in any case be calculated for the
actual forces acting on them. As a minimum, they shall be sized for 50% of the fully
loaded vehicle weight, even when there is no lift-off.
5.3 Track
The track design of a roller coaster shall comply with the following:
(a) Clearances to adjacent structures or parts of, or supports to, the track shall be such as
to comply with the requirements for clearances in AS 3533.1, when considered in
relation to the vehicles that are matched to the track.
(b) Track elements creating high accelerations shall take into account the tolerance of
patrons to magnitude, direction and duration of such accelerations.
NOTE: See AS 3533.1 for information on the effects of acceleration on the human body.
(c) The configuration of the track shall be such that for any condition of design loading
of the vehicle or train, the vehicle or train shall be capable of travelling the full length
of the track. The designer shall ensure that all critical characteristics (including
loading, rolling performance and wind and other environmental effects) for the roller
coaster configuration and any related start-up and test procedures are made clear in
the operations manual.
(d) The designer shall consider the following in the design of the track:
(i) For fixed location roller coasters, the effects of known wind conditions on the
motion of the vehicles or trains.
For mobile roller coasters, the effects of the specified operational design wind
speed when acting in the direction most adverse to motion of the vehicle or
train.
(ii) The peculiarities of motion pertaining to the lead and tail vehicles of a train
which are caused by track elements.
(iii) The safe and timely recovery of patrons and vehicles in the case of a failure
causing the vehicle or train to stall at any point on the track.

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AS 3533.4.3—2007 8

(iv) The characteristics of the motion of vehicles and trains at locations where
brakes may be situated and the resulting decelerations, occurring under all
conditions of braking, affecting vehicles and patrons and, in particular, the
reactive thrusts generated in the structure.
(v) The facilitation of regular inspection and maintenance (e.g. cleaning,
lubrication, and similar) of the entire length of the track and, in particular, anti-
roll-back and braking equipment.
(vi) The need for corrosion protection to track and substructure steelwork and
appropriate provisions to protect the internal surfaces of hollow members,
including drainage.
5.4 Elevators (lifts)—Machinery
The elevating means (lift) of a roller coaster shall comply with the following requirements:
(a) Where the failure of a continuous lifting element (chain, wire rope, or similar) would
result in that element, or some part of it, falling, whipping or otherwise presenting a
hazard to any person, positive means shall be taken to—
(i) remove power from the system;
(ii) prevent reversal of motion;
(iii) guard or contain unacceptable movements of the lifting element; and
(iv) control overloading of the drive so that under any circumstance, the factor of
safety applicable to the element cannot become less than 6 (ultimate).
(b) Lift machinery shall be housed in a manner that minimizes degradation due to
weather and shall be guarded in accordance with AS 4024.1 (series), with
consideration given to the requirements for regular inspection and maintenance.
NOTE: Machinery includes all sheaves, chain tracks, head and tail pulleys and chain wheels,
shafts and bearings, gearboxes and all other mechanical devices.
(c) Where vehicles or trains, rolling under gravity only, couple to an already moving
lifting element and no automatic synchronizing system is provided, then—
(i) the velocity of the lifting means shall be matched to the approach speed of the
vehicle or train to a close tolerance under average conditions; and
(ii) provision shall be made within the system to absorb or dissipate shock to
prevent damage to equipment or injury to patrons.
(d) For launch coaster, anti-roll-back systems shall be installed in accordance with
Clause 5.6.
5.5 Embarkation and disembarkation stations
Embarkation and disembarkation stations shall—
(a) be designed to minimize the clearance between the platform edge and the vehicle so
that—
(i) the clearance does not exceed 50 mm inclusive of wear tolerance at the point of
loading or unloading; and
(ii) no overlap of vehicles or parts thereof occurs above platform level;
(b) where traversed by patrons or operating staff, be surfaced in a slip-resistant finish
suitable for all probable operational weather conditions;
(c) be arranged so that the operator or attendant has a view (assisted if necessary) of
zones in which patrons or attendants could be at risk; and

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 9 AS 3533.4.3—2007

(d) be provided with appropriate barriers, controls or a combination of these so as to

ensure the safety of patrons while vehicles are absent from the
embarkation/disembarkation position in the station or when moving into or through
the station.
5.6 Anti-roll-back systems
Roller coasters shall be fitted with anti-roll-back systems at any location where reverse
motion of the vehicle on the track is unsafe.
The anti-roll back system shall—
(a) be capable of catching and holding the maximum load of the vehicle or train without
exceeding allowable stresses in any component or structure within the vehicle, train
or track, including the case of a fall back between catch points due to a missed catch
or failure of the first engaged device;
(b) be designed with redundancy to ensure against failure to act in the case of failure of
any component; and
(c) not subject patrons to accelerations that could cause injury, e.g. whiplash.
NOTE: See AS 3533.1 for information on the effects of acceleration on the human body.
5.7 Block zone system (anti-collision system)
Roller coasters that operate more than one vehicle or train at any one time shall incorporate
a system that prevents collisions. Such a system shall be automatic, and shall be fail-safe
under all foreseeable conditions, including malfunction of discrete components and power
loss.
NOTE: The block zone system requirement is not intended to be used in station manoeuvres and
does not prevent the shunting of vehicles through stations. Shunting is not considered a collision.
In the case of an automatic response to a pending collision, the block zone system shall
signal an alarm condition and shall require the intervention of the operator before allowing
any stationary vehicle to move.
In the case of a block zone failure, the block zone system shall lock out, signal an alarm
condition, and shall not be able to be reinstated without operator intervention.
Block zone systems shall have a safety integrity level of not less than 3 according to
AS 61508.1 unless a comprehensive hazard identification and risk assessment can
demonstrate that a lesser level achieves the same risk outcome.
Brakes that act to separate vehicles as part of a block zone system shall be safety brakes.
5.8 Braking systems and brakes
Braking systems shall be provided at any location on the track where vehicles or trains may
have to be halted or their speed controlled. Brakes shall operate within their intended
parameters under all weather conditions and all loading conditions for which the vehicles or
trains are designed.
Brake systems shall comply with the following:
(a) Under the condition of maximum braking effort, the deceleration rate shall be such as
to halt the vehicle in a safe manner without undue stress on any part of the vehicle,
restraint equipment or patrons.
(b) Safety brakes shall be fail-safe and designed to stop the vehicle or train in the most
adverse conditions. Safety brakes shall be one of the following kinds:
(i) Brakes operated (closed) by springs or similar devices and released (opened) by
means of pneumatic or similar devices.

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AS 3533.4.3—2007 10

(ii) Brakes operated by an energy source that retains the capacity to maintain
braking effort under the condition of general power loss, and controlled by
means that revert to a fully braked mode under loss of power. Such brakes shall
also have operating fluid pressure kept automatically controlled by the main
supply and a pressure drop in any one brake unit shall indicate a case of
emergency for the whole system.
All safety bakes shall comply with the following:
(A) The mechanical parts of the brake units are designed and calculated with the
appropriate safety factors stipulated in AS 3533.1 used as minimums.
(B) All functions and operational states of the brake system are controlled and
monitored by a fail-safe control system.
(c) Brakes shall be of such a design that, if the wear of the linings reduces the
effectiveness of braking, then the components that wear shall be able to be visually
inspected and monitored with ease.
(d) Where a reduction in braking effectiveness can compromise the safety of patrons,
automatic monitoring features shall be provided that indicate if that reduction has
occurred so the system can be shut down manually or is automatically shut down
from further operation.
(e) Brake assemblies, actuation gear and controls shall be readily accessible for
maintenance and inspection at all times. Where appropriate, remote ride lock out and
emergency stop facilities shall be provided on access platforms or accessways.
5.9 Control systems
Control systems applicable to roller coasters shall comply with the requirements for
controls, indicators and control stations in AS 3533.1 in addition to the following:
(a) Where any safety-related equipment relies for its integrity on a store of energy
(e.g. air pressure receivers, hydraulic accumulators), the control system shall prevent
the operation of the roller coaster unless the stored energy level is proved to be
satisfactory for the commencement and duration of the ride cycle.
(b) An emergency stop system shall be installed, which shall stop every moving vehicle
or train at the most immediate stopping device in the path of that vehicle or train, and
shall hold the position of any already stationary vehicle in the system.
(c) Any programmable electronic system, including sensing devices and associated
control circuits forming part of a control system on which the safety of the roller
coaster depends, shall—
(i) be designed, constructed and maintained to ensure compliance with an
appropriate level of safety integrity as determined by a risk assessment; and
(ii) be in accordance with AS 4024.1 (series) and its referenced standards.
(d) Where there is a critical wind condition identified by the designer in accordance with
Clause 5.3(d), which could affect the safe operation of a roller coaster, a wind
monitor shall be installed, which shall signal an alarm to initiate cessation of
operation.
(e) Ride cycle, lap or start counters shall be installed.

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 11 AS 3533.4.3—2007

6 OPERATION AND MAINTENANCE

6.1 General
The instructions and requirements provided by the manufacturer and any provided by the
supplier shall be followed, particularly in relation to installation, operation, maintenance
and inspection. In the absence of such information, the roller coaster shall not be used until
documentation containing the necessary information has been obtained from the
manufacturer or supplier or a competent person.
6.2 Operation
The requirements for assembly and operation of an amusement ride set out in AS 3533.2
shall apply to the operation of a roller coaster and, additionally, weather conditions shall be
continuously monitored. If the wind conditions reach the critical condition identified by the
manufacturer or supplier, the ride shall be cleared and operations ceased immediately.
6.3 Modification
The combination of vehicles or trains, and the track on which they run shall not be altered
without the written permission of the designer or a competent person.
6.4 Inspections
6.4.1 General
All roller coasters shall be subject to inspections of the types set out in AS 3533.3, carried
out by competent persons, in accordance with AS 3533.2. In addition, the inspection regime
shall address the content of Clauses 6.4.4 to 6.4.7 inclusive, unless varied by a competent
person.
Roller coasters of classification 3 or higher according to AS 3533.1, shall be subject to the
types of inspections listed in Clauses 6.4.2 and 6.4.3. The content of the inspections and
tests shown in these Clauses shall be addressed as a minimum, where applicable to the
particular design, unless modified or extended by the instructions of the manufacturer or by
a competent person.
6.4.2 Inspections for steel track roller coasters
6.4.2.1 Daily inspections
Daily inspections shall be carried out before operation each day. Daily inspections shall
cover the following aspects:
(a) Track The entire track shall be visually inspected to ensure there are no foreign
objects in the area between the rails and the upstop wheel clearance envelope, or
within the train path clearance envelope. While inspecting the track, the track
members, bolted connections, support structures and welded connections shall be
observed for signs of loosening, cracking or other unusual problems.
This visual inspection shall be conducted in a manner that is sufficient for a
competent person to recognize obvious faults and shall be conducted from readily
accessible locations in the best proximity to those features of the track which are
designated as critical.
NOTE: Binoculars, mirrors, or other means may be used to enhance an adequate view.
(b) Anti-roll-back systems Anti-roll-back systems shall be checked for security and
condition.
(c) Handrails, walkways, steps and platforms All walkways, handrails, steps and
platforms shall be inspected to ensure they are in good order.
NOTE: Post assembly inspections of transportable equipment include the structural soundness
of these features.

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AS 3533.4.3—2007 12

(d) Block system The integrity of the block system shall be tested by an established
procedure.
(e) Brakes Brakes including emergency brakes, shall be checked for function. Station,
trim and stopping brake linings shall be inspected.
(f) Control systems The emergency stop function shall be tested by an established
procedure.
(g) Stored energy devices All stored energy systems required for emergency situations
shall be checked for their state of charge.
(h) Vehicles or trains The condition of the vehicles or train and the integrity of the
restraint system shall be checked. An inspection regime shall be developed and
implemented for vehicles and trains.
NOTE: The following should be considered for inclusion in the daily inspection of vehicles or
trains:
(a) Harness lock and release mechanisms for correct function.
(b) Secondary restraint mechanisms.
(c) Body and seating mount fixings and hardware.
(d) Seat, harness and vehicle padding.
(e) Road, upstop and guide wheel wear and condition.
(f) Road, upstop and guide wheel clearances (visually).
(g) Road, upstop and guide wheel bearings.
(h) Coupling safety straps, fasteners and cabling.
(i) Chassis coupling points on trains.
(j) Braking equipment.
(k) Anti-roll-back equipment.
(l) Carriage pick up or drive equipment.
If an unsatisfactory result is indicated on any item, the matter shall be referred to a
competent person for determination or rectification prior to the device being released for
service.
6.4.2.2 Designer and manufacturer stipulated inspections
Where inspection and test procedures are mandated by the designer or manufacturer at
regular intervals, roller coasters shall be subject to such inspections in accordance with
AS 3533.2.
6.4.2.3 Annual inspections
The inspections set out in this Clause shall be carried out on an annual basis and during a
major inspection. The annual inspections may be completed in accordance with an
inspection and test plan carried on throughout a year period provided that the plan has been
determined by a competent person to comply with the requirements for annual inspection
given in this Clause. Advice should also be sought from a competent person as to the need
for some of these inspections to be carried out more frequently than once per year based on
the ride’s design, location, usage pattern and past history. Annual inspections shall cover
the following aspects:
(a) Track A close visual inspection of the following areas shall be carried out:
(i) All welds tying the running rail back to the main support structure in high
acceleration areas and inverted elements of the track.
(ii) At least 20% of all remaining welds on a rotational basis.
(iii) All running surfaces for road, guide and upstop wheels in high acceleration
areas and inverted elements of the track.

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 13 AS 3533.4.3—2007

(iv) All previous repairs and replacement areas.

(v) All column base plates and welds to the columns and gussets.
Where track can suffer thinning, thickness testing shall be carried out on the highest
acceleration areas of the track, those areas particularly subject to corrosion and at
least 20% of all remaining running surfaces for road, guide and upstop wheels on a
rotational basis.
NOTE: Appendix A provides information on determining high acceleration areas.
Track gauging shall be carried out through high acceleration areas to ensure operating
tolerances are maintained.
NOTE: Comparative gauges from points of major support and at three points in between
should show if there is any reason for more detailed investigation.
Bolted, pinned and welded connections on track and framework shall be visually
checked for security, significant corrosion and lack of corrosion protection.
Where close visual inspection results in indications of faults, appropriate means such
as non-destructive testing shall be employed to determine the extent of faults and to
determine subsequent repairs.
In the event of a serious crack indication in the support framework, a thorough
inspection of that frame and each adjacent frame shall be conducted.
(b) Anchor bolts An inspection of base plate anchor bolts shall be made in order to
verify that anchor bolts are intact throughout their length. 20% of anchor bolts in high
g force areas, inverted elements of the track and areas where they can be affected by
unusual high corrosion shall be tested on a rotational basis using ultrasonic testing
ensuring that all bolts in these areas have been checked within a 5-year period.
5% of all remaining anchor bolts shall be tested on a rotational basis.
NOTE: Ultrasonic testing is recommended but proof loading may be used provided that the
configuration of the bolts and base plate is known.
(c) Base plate grouting The grout under the base plates shall be visually inspected to
ensure there is no excessive cracking and to ensure that the base plate remains in
contact with the grout.
NOTE: This is best observed whilst the device is operating.
(d) Handrails, walkways, steps and platforms All walkways, handrails, steps and
platforms shall be inspected to ensure they are in good order and structurally sound.
(e) Brakes All bolted and welded components shall be visually inspected annually.
Where there is a superficial sign of failure or defects, appropriate NDT techniques
shall be employed to determine the extent of any defect, and a competent person shall
specify the appropriate repairs to be carried out.
All components such as bolts and nuts, reaction arms and anchors, hydraulic hoses
and their fittings or connectors shall be inspected for wear, loosening, cracked welds
or unusual conditions. Air hoses shall be examined for signs of general degradation,
wear, abrasion or cuts that can cause failure.
Air leaks, air pressure settings and lining condition shall be checked.
(f) Mechanical systems All pneumatic or hydraulic systems shall have their lines
checked for integrity and condition.
(g) Vehicle inspections A visual inspection shall be carried out in accordance with the
daily inspection requirements. NDT shall be carried out in accordance with
Clause 6.4.7.

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AS 3533.4.3—2007 14

(h) Intrusion hazards All items capable of intruding the ride envelope if their support
mechanism failed shall be inspected to ensure support adequacy. The potential effects
of local weather conditions shall also be considered.
NOTE: Examples of items that can cause problems include trees, signage, lighting, theme-
work and cabling.
(i) Anti-roll-back equipment Welds and hardware securing anti-roll-back equipment to
the main structure shall be checked.
NOTE: These can include ratchet and pawl, sprag clutch with friction wheels, brake motors or
other similar systems on both incline and vertical lifts.
If there are non-conformance issues, further action should be taken as deemed appropriate
by a competent person.
6.4.2.4 Major inspection
The major inspection regime set out in this Clause shall be carried out in accordance with
the requirements for major inspections in AS 3533.2. In addition to the inspections set out
for annual inspections in Clause 6.4.2.3, the scope of a major inspection shall include the
appropriate inspections from the following as selected by a competent person:
(a) 20% of all welded connections of the rails and from the rails to the main structure in
the high g and inverted sections and 5% of all other areas shall be inspected using
appropriate NDT techniques.
(b) Close visual inspection of all welds not covered in the most recent annual inspection
in accordance with AS 3978.
(c) Close visual or spanner check inspection of all bolted connections.
In the event of a serious crack indication in the rail tube, a length of track equal to three
times the rail gauge shall be thoroughly inspected each side of the original defect.
In the event of a failure within a bolted joint, all bolts in that joint shall be removed and
checked and an investigation of the cause of the failure shall determine further action.
NOTE: Further action may include checking all bolted joints of that type.
6.4.3 Inspections for wooden roller coasters
6.4.3.1 General
Where this Clause does not detail the inspection required for items that are common to both
steel and wooden roller coasters, e.g. block systems, the provisions for inspection given for
steel roller coasters shall be incorporated in the inspection for wooden roller coasters.
Wooden roller coasters may be categorized as those having tracks supported on timber
structures and vehicles, singly or in trains, that are constructed with metal chassis or a
timber chassis with metallic wheels and bearing arrangements, draft gear, roll-back and lift
engagement equipment.
The inspection of wooden roller coasters involves two distinct activities, firstly the
inspection of track, track-mounted control facilities and sub-structure and secondly that of
the vehicles. Competent persons shall be selected to undertake all inspection work and shall
be given the appropriate facilities to achieve reliable results.

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 15 AS 3533.4.3—2007

6.4.3.2 Daily or pre-operational inspections

Daily and pre-operational inspections shall be carried out before operation and cover the
following aspects:
(a) Track Where the track is provided with walkways, it shall be closely visually
inspected from such walkways. Where the track is not accessible by walkways, its
observation shall be undertaken from points that together provide for a view of its
entire length so that features can be reasonably observed and, where any doubt exists,
measures shall be taken to obtain close visual inspection. The track inspection shall
be undertaken to encompass the following in a manner designed to reveal any obvious
faults or hazards:
(i) Obstruction by foreign objects.
(ii) Displaced or lifting steel running surfaces particularly at joints.
(iii) Displaced or distorted roll-back rack elements.
(iv) Loose and protruding running surface fasteners (screws and bolts).
(v) Loose bolts in general.
(vi) Damaged and dislodged timber laminations, guide members or other elements
of the track bed.
(vii) Loose and damaged duckboards, handrail members, siding or other protective
structure above or beside the track.
(viii) Any evidence of track distortion due to sub-structure movement and any
evidence of out of gauge (e.g. by observing wheel tracking marks).
(ix) Lift chain or rope condition for obvious damage, out of line links or cranks.
(x) Chain track condition and lubrication or rope tow sheave damage.
(xi) Sub-structure damage such as splits or collapse of posts, ledgers, ties and
braces as can be observed remotely from track level.
(b) Track sub-structure Observation of the sub-structure shall be carried out from
foundation level, aided where appropriate, by binoculars or other devices, and from a
complete circuit around the track or from sufficient accessible locations to ensure that
a competent person can recognize any obvious faults or hazards. The inspection shall
include checks for evidence of the following faults or hazards:
(i) Missing bolts (on ground).
(ii) Protruding/migrating bolts.
(iii) Loose and pendulous timbers.
(iv) Collapsed timbers.
(v) Cracked and distorted timbers (not shakes or original degrade) observations
based on recent changes.
(vi) Footing or stump movement and sinking.
(c) Brakes and lift Observation and test of all vehicle control elements such as brakes
and lift machinery shall be sufficient to reveal if any of the following faults or
hazards exist:
(i) The dislodgement of brake lining material, lift chain or rope from guide tracks
or from chain wheels or sheaves.
(ii) Brake bar distortion.
(iii) Air or hydraulic line damage.
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AS 3533.4.3—2007 16

The inspection shall also check if—

(A) air pressures are correct;
(B) gauges are intact and operational; and
(C) all brakes and lift machinery provide the correct action mechanically.
(d) Checks and tests of cars or trains Cars and trains shall be checked while parked to
reveal any of the following faults or damage:
(i) Damage to seats, side panels, hand-bars and bodywork such as could cause cuts
and abrasions.
(ii) Visually evident damage to wheels and bogies.
(iii) Visually evident damage or connection errors for draft gear, couplings and
safety chains and ropes between cars.
The inspection shall also include the following:
(A) All operational cars and trains shall be despatched from the station and, where
appropriate, shall be checked for running times by direct timing or by the
observations of an experienced person. No car or train shall be put into service
if extended checking and inspection of it does not satisfy minimum passage
times.
(B) The action of trim, pre-station and station brakes shall be checked in respect to
every operational car or train.
(C) The control system operator interface shall be checked to prove the
functionality of each control or signal device.
(D) Any ancillary devices, e.g. anemometer, shall be verified as operational.
(E) Restraint equipment including locking and releases, whether manual, foot or
remote or combination actuated, shall be proved to provide proper operation.
6.4.3.3 Regular inspections
Regular inspections shall be carried out in accordance with the following requirements:
(a) Track and sub-structure Because of the extent and complexity of track and sub-
structure typical for wooden roller coasters, it is not practical to specify the intervals
for or the exact content of regular inspections.
A preventative inspection and maintenance program shall be established for every
wooden roller coaster covering the structure of the track and its supports. This
program shall be devised by a competent person on the basis of, but not limited, to
the following:
(i) The manufacturer’s instructions.
(ii) The age and history of the ride, in particular its structural performance.
(iii) The usage and duty of the ride.
(iv) The environment and climatic conditions existing at the site.
(v) The design details and engineering specifications of the ride, including the
following:
(A) The original specified materials within the track and sub-structure.
(B) The jointing techniques.
(C) The availability of replacement materials in respect to species and grade.
(D) The original preservative methodologies.

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 17 AS 3533.4.3—2007

(E) Alternative preservative methodologies.

(F) The recommendations of AS 1720.1.
The preventative inspection and maintenance program shall be organized so that
degradation of track and sub-structure, including footings, is monitored sufficiently
thoroughly and repairs and replacements made to ensure that it remains capable, over
its full extent, to safely support fully loaded vehicles travelling at full speed at all
times.
(b) Brakes and lift machinery Regular inspections on brakes and lift machinery shall
include the following:
(i) Braking equipment including brake mechanisms and linings, brake actuator,
actuator supply lines, valve gear receivers and air/hydraulic supply equipment
(or equivalent) shall be inspected thoroughly and tested at intervals set to
forestall any fault but not less than twice per year or operating season.
(ii) Lifting machinery, whether chain, wire rope, friction drive or other type, shall
be monitored by appropriate means (e.g. power demand variations, visual)
sufficiently regularly to reveal and forestall any fault that could endanger
patrons (e.g. chain break).
(iii) Where a manufacturer’s specification exists, it shall be followed or the means
and regularity of checking shall be established by a competent person.
(c) Cars and trains Cars and trains shall be subject to regular inspection and
maintenance according to the manufacturer’s instructions or those prepared by a
competent person, which shall take particular note of the following:
(i) Brake fins or bars.
(ii) Anti-roll back equipment.
(iii) Lift engagement devices.
(iv) Draft gear and safety links.
(v) Restraint devices, locks and release mechanisms.
6.4.3.4 Annual, major and special inspections
Annual, major and special inspections of wooden roller coasters shall be carried out in
accordance with AS 3533.3 and, where existing, instructions of the manufacturer or a
competent person.
Annual inspections shall be carried out or supervised by a competent person not normally
associated with the roller coaster and shall include a review or audit of the preventative
inspection and maintenance program.
6.4.4 Brakes
Acceptable stopping distances to be used when assessing the performance of brakes shall be
set and documented by either the manufacturer or a competent person, along with the
procedures for such assessments.
NOTE: Procedures should indicate the load conditions to be used during brake testing.
6.4.5 Electrical systems
The inspection of electrical systems shall comply with AS/NZS 3000 and the electrical
inspection requirements in AS 3533.3. Testing of electrical systems shall comply with
AS 60204.1 where appropriate.

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AS 3533.4.3—2007 18

6.4.6 Corrosion
Where water intrusion is possible to the internal void spaces of columns, track ties, track
rails or ancillary structural components, a competent person shall assess whether thickness
testing on a regular basis is required.
6.4.7 Non-destructive testing (NDT) of single point critical failure components
The regimen for critical failure components detailed in AS 3533.3 shall be applied unless
other testing frequencies are specified by a competent person based on a record of
performance in relation to fatigue cracking.
Examples of components that may need annual NDT are as follows:
(a) Harnesses and attachments.
(b) Interconnection pins (couplings).
(c) Wheel carriers including fixings, bolts and pins.
(d) Road, upstop and guide wheel axles.
(e) Wire ropes and cables.
(f) Body attachment bolts and pins.
(g) Brake componentry and attachment points.
(h) Pick up or drive equipment and the attachment points.
(i) Anti-roll-back equipment.
20% of chassis structures should be tested on annual basis so that within a 5-year period all
have been tested.
6.5 Maintenance
6.5.1 General
The maintenance of roller coasters shall be carried out in accordance with AS 3533.2 and
the instructions of the manufacturer or supplier or, where these are not available,
procedures and instructions prepared by a competent person.
6.5.2 Corrosion
All equipment shall be maintained free of corrosion that affects the structural integrity of
the device.
6.5.3 Repairs
All welding repairs that have been assessed to be critical shall, as a minimum, meet the
requirements for structural purpose (SP) welding in accordance with AS/NZS 1554.1.
Consideration should be given to welding for fatigue loading situations in accordance with
AS/NZS 1554.5. Welding shall be carried out by a welder qualified for the procedure. All
other repairs shall be carried out by competent persons in accordance with the requirements
for maintenance, replacement, alteration and repairs in AS 3533.2.

 Standards Australia www.standards.org.au

 19 AS 3533.4.3—2007

APPENDIX A
HIGH ACCELERATION AREAS AND INVERTED ELEMENTS
(Informative)

A1 SCOPE
This Appendix provides information on how to determine the location and extent of
inverted elements and high acceleration areas.

A2 INVERTED ELEMENTS
The commencement and end point of an inverted element of track are taken to be the lowest
points of track immediately before and after the inversion. High acceleration areas typically
extend out beyond these low points in each direction. Paragraphs A3 and A4 provide ways
of determining the high acceleration areas on a ride.

A3 ACCELEROMETER RUN RESULTS

Accelerometer run results can be reviewed and the high acceleration areas identified as
where any of the following are observed:
(a) Vertical acceleration above 3.0g.
(b) Lateral acceleration above 1.0g.
(c) Areas with a lateral ‘jerk’ over 10g measured as change in acceleration per second.

A4 COMMON LOCATIONS OF HIGH ACCELERATION AREAS

High acceleration areas are most likely to occur at the following locations:
(a) Major pullout areas at the bottom of hills.
(b) Entry and exits areas around inversions.
(c) Horizontal curves where lateral forces push riders into the sides of their seats.
(d) Any area where there is a quick change in acceleration causing a noticeable bump or
jolt when riding in the coaster.

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AS 3533.4.3—2007 20

NOTES
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