Blackpool Pleasure Beach uses Tekla Structures for The Big One roller coaster renovation

Blackpool Pleasure Beach chose Taziker Industrial to assist in renovating and refurbishing its renowned roller coaster, The Big One. They recognized digital technology's significant role in this project and turned to Trimble for support.

Originally opening in 1994, The Big One is considered one of Blackpool Pleasure Beach's most famous rides. With a towering height of 235 feet, it still holds the record as the tallest rollercoaster in the UK. However, after celebrating its 25th anniversary in 2019, Blackpool Pleasure Beach enlisted the expertise of Taziker Engineering Services to design, manufacture, and install four new steel track sections measuring a total length of 45 meters as part of their annual maintenance program.

Reflecting on the project, Jarrod Hulme, Managing Director at Taziker Engineering Services, remarked: “We were truly honored and privileged to be awarded this contract by Blackpool Pleasure Beach, especially considering it marked one of our company's first ventures into the field of structural steel engineering."

“I think this project serves to really highlight the benefits of this new digital age that we within the construction and engineering industries find ourselves in. Through new technologies and the uptake of BIM, we are able to streamline processes, ensure high levels of accuracy, reduce risk and minimise the likelihood of human error – all incredibly valuable accomplishments both off and on-site.”

Jarrod Hulme, Managing Director, Taziker Engineering Services.

In the past, replacing a section of roller coaster track without digital technologies was both time-consuming and risky. It involved project teams having to first remove the track section, manually measure hundreds of dimensions, and then use these measurements to create a 2D drawing. The new steel section would then be fabricated based on this drawing. Understandably, this process would have taken a significant amount of time and there would have been a high potential for human error. Additionally, it would have forced the theme park to close for an extended period while the work was being done – something unimaginable today.

Alongside Tekla Structures, Taziker also employed the Trimble SX10 on the project. This scanning total station combines surveying, imaging, and high-speed 3D scanning all in one instrument.

"Using the Trimble® SX10, we were able to take a 3D point-cloud survey of the whole area in question, which measured 60 metres in total and included the ground, support columns, steel connections and the sections of track. This provided us with a huge amount of data of the existing site and structure, which we knew we could trust to be highly accurate.”

Jarrod Hulme, Managing Director, Taziker Engineering Services

Intelligent Trimble hardware and software has proven to be highly effective in collecting and organizing thousands of cloud points, ultimately creating a recognizable model of the track and its surrounding site. The software's automatic cleanup feature removed extraneous points unrelated to the track, such as those related to trees, vehicles, or people, from the cloud survey.

The direct link between the Trimble hardware and Tekla Structures has enabled the data to be seamlessly imported into the modeling design software, which in turn has been instrumental in the creation of a 3D model of both the existing and new sections of track while also ensuring accuracy in track dimensions and geometry. Taziker could fabricate the new steel to within a remarkable 2mm tolerance.

Read more about Tekla's open approach to BIM

Digital technology played a pivotal role in improving the track beyond simply replacing the old section with a like-for-like version. By leveraging the intelligent tools within Tekla Structures, Taziker addressed the wear and tear of the steel tracks, which had endured numerous impacts, bumps, and structural vibrations over 25 years of operation. Moreover, previous remedial works had installed short, straight steel sections, contributing to the curvature of the track being less smooth than before.

All in all, the innovative use of Trimble hardware and software, along with Tekla Structures' intelligent tools, have played an integral role in Taziker's ability to successfully revamp the track and provide riders with an even more enjoyable and smoother experience.

Using the cloud-point survey and Tekla Structures, Taziker could take three points on the model and successfully smooth out the curve between these selected points while ensuring the existing coaster's continuation.

Installation occurred on-site during Blackpool Pleasure Beach’s off-peak season, where the old section of track was removed, and the new section was lifted and fixed into position.

Jarrod continued: “The on-site installation was a smooth and seamless process, with the track sections fitting into place perfectly - again, thanks to the digital workflow employed on the project and the incredible accuracy of our 3D data and model."

“Indeed, in my experience, installation is an area of a construction or engineering project where the benefits of BIM can be felt. When discussing BIM, people often refer to clash detection, but usually only in the context of clashes between structural components. However, I have found that this clash detection can also be applied to planning a successful on-site installation, including managing the position of plant machinery, such as cranes, and ensuring that they have the necessary room to maneuver. This can be a challenge in urban developments or crowded sites, such as at Blackpool Pleasure Beach, where numerous space constraints and restrictions may exist. Carrying out a 3D survey of the wider site can be hugely beneficial, allowing you to incorporate the context of the whole site into your BIM model and providing you with the ‘bigger picture’. On a previous Taziker project in Blackpool, we could even use Trimble’s technology to simulate crane movements and lifts before getting onto the site – something that would previously have been impossible to do.

“Throughout my time in the construction and steel engineering sector, I have seen this 3D working method and BIM software, such as Tekla, transform the industry. I think it’s precious on time-critical projects with a limited window of opportunity to carry out work, whether here in Blackpool or on a road or rail infrastructure project.

In many ways, BIM gives you a digital rehearsal of the works, allowing for more efficient and informed planning. It also provides you with the assurance of high levels of data accuracy, which is especially important considering it is this data that is then transferred and used throughout a project, from initial design to fabrication and on-site assembly.

“Incorporating BIM software, such as that offered by Tekla, into our workflow also helps to minimize risk. As a contractor, you are liable if a project exceeds the allotted timescale or budget, whether due to design or fabrication errors or rework being required. Through digital technology, we can ensure that works are carried out correctly and safely, and projects are delivered on time.”