Oklahoma Department of Labor Brenda Reneau COMMISSIONER EXECUTIVE SUMMARY October 24, 1997 An April 20, 1997, accident on the Wildcat roller coaster at Bell' s Amusement Park in Tulsa, Oklahoma, resulted in the death of one person and injury to five other individuals. The responsibility of investigating the incident fell to the Oklahoma Department of Labor which, as a result of legislative action, has jurisdiction in the matter. During the course of the next six months, the Oklahoma Department of Labor (ODOL) conducted an intensive and exhaustive investigation. Every effort has been made to maintain the integrity of the evidence, eyewitness statements and employee testimony relevant to the investigation. As the largest and most comprehensive investigation ever conducted by this agency, the process was methodical, deliberate and cautious. The professional services of Zahl-Ford Engineering and Emtech were retained to provide technical expertise. Along with ODOL investigators and ride inspectors, Zahl-Ford and Emtech performed numerous tests both on-site and in a laboratory in our endeavor to determine why the accident occurred and to develop recommendations designed to prevent such a tragic event from occurring in the future. The Zahl-Ford and Emtech results and recommendations are contained in this final report. From the onset, the primary cause of the accident appeared to be the failure of the Wildcat's anti-rollback device. The ODOL set out to determine why the coaster's non-redundant safety mechanism failed to work as designed. Numerous theories were considered and systematically dismissed. Investigators attempted to recreate the events which are believed to have contributed to the accident. Answers were sought to many questions, chiefly, how did the black car prematurely disengage the chain necessitating the use of the anti-rollback device on the chain hill? A number of contributing factors were present at the time of the accident. The "chain dog" which engages the chain at the base of hill was located higher on the black car than the other Wildcat cars. The wheels on the black car were newer with less wear which increased the height of the "chain dog" in relation to the chain. The "chain dog" had been removed and sanded down after it had apparently pulled the chain off the sprocket one week before the accident. The chain, itself, differed from other Wildcat roller coasters still in operation in that it would 'lay over' after clearing the sprocket at the base of the hill. Other concerns centered around maintenance and maintenance personnel. Bell's Amusement Park doesn't possess a copy of the Wildcat 's Operating Instructions. The park had no written record of repairs or routine maintenance performed on the Wildcat prior to buying it and didn't maintain records of repair or maintenance conducted during their ownership of the ride. Maintenance workers had no formal mechanical or technical training in amusement rides. The park's maintenance supervisor testified he had no established procedure or protocol for verifying work performed or the quality of the job. The Wildcat's manufacturer, Schwarzkopf GmbH, no longer makes roller coasters. Unable to find some parts or to cannibalize other roller coasters for parts, Bell's personnel began fabricating unavailable parts on-site. This practice contributed the primary factor for failure to prevent the accident. Bell's chose a plastic material of dissimilar properties for use in the car's anti-rollback device. On April 20, 1997, the Nylatron plastic insert fabricated in Bell's maintenance shop shattered, allowing the car and its three occupants to free-fall backwards down the chain hill. The inappropriately brittle material is wear resistant, but it is not recommended by its manufacturer for use in non-redundant safety devices like the Wildcat's anti-rollback device. The investigation brought to light other concerns which have been addressed in this report. The testimony of park employees indicates no formal training exists for ride operators. The park personnel office contains no record of employee training or proof of an employee's competency and ability to properly operate a given ride. The ODOL Safety Standards division has implemented some steps in an effort to reduce the individual, personal risk associated with amusement park rides. The Amusement Ride Safety Act requires at least one ride inspection, annually. The ODOL is already exceeding this minimum. In addition, to inspecting and certifying rides before the start of the State Fairs in Oklahoma City and Tulsa, the ODOL instituted a surveillance program for the two events. During a 20 day period, 58 re-inspections were performed resulting in 69 additional repair orders. Inspectors also issued 23 operational warnings which included: disregarding height restrictions, undermanned rides; and, operator inattention. The report contains recommendations which will require either legislative or administrative action to affect change. The amusement ride industry is highly unregulated. It is unlikely the efforts of the Oklahoma Department of Labor, alone, will have much impact outside our jurisdiction. Although Oklahoma has among the most stringent amusement ride laws and rules in the country, it was not enough to prevent a tragic event from occurring. The general public may have on a false sense of security regarding amusement rides. The lack of national standards should not be considered lightly in an industry which charges admission to "safely" scare its patrons. Accidents can happen and safety is neither a certainty nor a guarantee.