Mention 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 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, jib cranes, gantries, lift tables, pneumatic lifters and transfer carts are commonly used in these dynamic maintenance environments.”
To run through some of these in more depth, bridge cranes are best suited to heavy, longtravel lifts, whereas jib cranes are used to move and position items within a smaller workspace. Pneumatic lifters are devices powered by compressed air or vacuum pressure, suitable for lifting heavy loads in harsh environments.
No need for accolades
The challenges peculiar to theme parks are challenges that CraneTech knows well. CraneTech, which has more than 30 service locations nationwide, including an Orlando branch, recently worked on a difficult theme park project that many other companies passed over.
“CraneTech was engaged to support a project for a large theme park ride that had stalled after another vendor determined they could no longer fulfill the scope of work,” says Ring. “This was a high-pressure project tied to a nationally reported ride closure – one many firms declined due to risk and visibility. With peak season under way and limited options remaining, the park required immediate action after multiple service providers declined the request. CraneTech stepped in to deliver a solution.”
This was no easy task. Since another company had started the work, CraneTech had limited access to the original scope and pre-planning phase. They were also faced with incomplete power installation, ongoing mezzanine construction, restricted operating days and missing components. However, CraneTech diligently pressed forward. They coordinated closely with all stakeholders, sourced all the materials they needed and executed the work safely and efficiently alongside other trades.
“Taking over the project, we installed the required motors and power bar, then completed final load testing and certification for the previously installed 10t overhead crane,” says Ring. “Our team integrated seamlessly with park leadership, the general contractor and multiple trades working concurrently within the facility. We began with a comprehensive inventory and site assessment, followed by close coordination with project and park leadership.”
He notes that projects of this nature rarely bring public recognition. After all, if the work is done well, the public will just see that the ride is functioning as it should – they won’t have any sense of all the effort that was expended behind the scenes. Still, the work brings its own kind of satisfaction.
“Its successful completion was only possible due to the great efforts of our field technicians, technical solutions team and support staff. Their decades of experience, commitment to safety and customer-first mindset was critical to developing a plan to complete this work safely within a tight timeline. It was a great demonstration of CraneTech’s commitment to always putting our customers first, and truly partnering with them to ensure the safety of their people and their operations,” says Ring.
Safety first
Theme park clients are looking for safety first and foremost. This is one industry where any safety breaches could prove very serious, not to mention reputationally damaging. Over the past decade or so, there have been a handful of troubling incidents at Florida theme parks. Recent cases include the sad death of a man in Universal’s new Epic Universe theme park, in September 2025. Five others, who had ridden on the same rollercoaster, have filed lawsuits alleging “severe and permanent” injuries.
Two months later, a worker at Walt Disney World was hit by a runaway fake boulder during the Indiana Jones Runaway State Spectacular. The staff member, who was trying to stop the 400lb prop from rolling into seated spectators, ended up with fractured vertebrae and a head injury.
While cases like this are certainly rare, any non zero number is too many, and accidents tend to grab headlines – with obvious implications for the theme park’s bottom line. For a crane company, that means taking a proactive approach to hazard management, showing the park they’re fully aligned with its safety culture.
“Safety is at the forefront of everything we do,” says Ring. “Our local branch teams start every morning with a toolbox talk where they discuss a safety topic each day. And on a jobsite, every member of our team is always thinking safetyfirst. Our entire team is trained to identify hazards, think beyond the task at hand and speak up with informed solutions. This approach challenges the traditional vendor-client model and enables decisive, collaborative action that goes beyond being just a service provider.”
He adds that CraneTech delivers proactive, results-driven planning for overhead lifting systems in ride and show environments. All its services are executed with safe, efficient response times and minimal operational disruption. This helps attractions remain reliable, on schedule and safe for guests.
“Our industry-leading services are custom-tailored and include engineered electrical and mechanical solutions, custom lifting devices, critical structural repairs, engineering support and specialised inspections and studies,” says Ring. “We also develop prescriptive safety, maintenance and inspection programmes that meet or exceed OEM and regulatory requirements, reducing the risk of unplanned peak-season failures.”
Up to standard
Unsurprisingly, a big part of the job involves understanding the relevant regulations and safety standards. In the US, these are defined by the Occupational Safety and Health Administration (OSHA), which sets the standards for safe and healthy workplaces. There are a few key regulations that are particularly relevant for theme parks.
First is the General Duty Clause, applicable to all workplaces, which mandates that workplaces be free from recognised hazards. Most theme parks support this clause through clear safety signage for guests and personnel. Meanwhile, the standards specific to theme parks are covered under 29 CFR 1910.
“Specific standards under 29 CFR 1910.212 address the safe design, construction and maintenance of amusement rides to help prevent accidents – an area where CraneTech serves as a valuable partner,” says Ring. “In addition, OSHA’s lockout/tagout and fall protection regulations ensure our technicians can work in full coordination with park staff while maintaining the highest safety standards.”
Another relevant section is 29 CFR 1910.179, which covers the requirements for design, application, inspection and service of overhead and gantry cranes. For instance, it specifies that ‘where passageways or walkways are provided obstructions shall not be placed so that safety of personnel will be jeopardised by movements of the crane’.
Then there’s ASME B30.2, which carries standards and requirements for equipment not covered under 1910.179. There are also likely to be a patchwork of state and local regulations, as well as specific operating procedures from the equipment manufacturer.
Finally, OSHA has established strict fall protection standards, which apply to those working at height. Clearly, that’s going to include people operating cranes and hoists at theme parks.
“These standards cover anchor points, personal protective equipment and the use of mobile elevated work platforms (MEWPs),” says Ring. “Our technicians are extensively trained, and certified through our own training school, to ensure full compliance with these requirements while operating in demanding environments.”
For instance, CraneTech will establish clearly marked safety zones, by installing safety barricades to control all access to the hazard areas. When equipment can’t be accessed by traditional MEWPs, they will employ lifeline systems. They also coordinate closely with the park maintenance and safety teams, to apply park standards on top of their own well-attested safety protocols.
“One widely adopted safety protocol is our line-of-sight requirement with a single point of direction,” says Ring, by way of example. “A trained, ground-level operator maintains continuous visual contact with technicians and has authority to stop work, cancel a lift, and communicate with all personnel within or near the safety zone.”
Any time the team carry out a service, repair or installation, they do so with a keen eye to potential hazards.
“At CraneTech, each job begins with a job hazard analysis (JHA) to identify potential risks, their location in the workflow and the best ways to control or minimise exposure,” he says. “The JHA is then reviewed with all team members involved, ensuring everyone understands the hazards, controls and each step of the job before work begins.”
This process relies on thorough pre-planning, as well as on clear and open communication between everyone involved. Work areas must be secure, MEWPs must be operated safely and lockout/tagout procedures must be rigorously followed. (These are safety procedures followed during maintenance, to prevent unexpected startup of rides, as well as electrical shock or other hazardous energy release.)
“Technicians are trained to avoid the direct path of components when troubleshooting cranes and other machinery, further reducing exposure to hazards,” says Ring. “During work, if conditions change, new hazards are identified or personnel are swapped, a ‘stop work’ event is initiated to reassess the JHA and determine any corrective actions required. This structured approach ensures safe, controlled and efficient operations at all times.”
High stakes
These types of considerations are front of mind for a company like CraneTech. However, they’re issues the average park visitor would never be aware of. If they do notice an overhead crane or hoist as they wander through the theme park, they aren’t likely to pay much attention. What’s a crane when you have magical turrets to gaze upon, or a photo opportunity with Minnie Mouse?
Little do they realise that cranes and hoists have been central to their experience all along, and that without this equipment, the park attractions would never have got up and running in the first place. Crane operators, inspectors and technicians certainly have a lot to be proud of – but there’s a lot at stake for them too.
“Working in a theme park can be very challenging. But our team takes great pride in knowing that our work helps theme parks operate safely with minimal disruption, which brings satisfaction to parkgoers from around the world,” says Ring.
