As far as the track support discussion goes let me start off by saying that I have never seen the supports close up, I know no one who works at SM, and I have never seen any construction schematics etc... for SM.
However, being in the industry I find it unlikely and almost impossible that any type of refurb would be going on if there was even a hint of track support failure. This isn't just about a lawsuit if someone gets injured. The engineers, architects, contractors etc... can also be held criminally liable if an accident happens that could have been prevented if it is proven that people knew about it yet did nothing.
If there was even a remote analysis of the supports that concluded fatigue had weakened the structure and failure was possible things would not proceed until corrected. It seems like there is a misconception that us folks in the construction industry dont pay attention to stuff like this but in reality we do. If they know there could be a problem with the supports, they would fix it.
I know that some accidents happen, but if the supports were really bad enough for people on an internet forum to "know" about it. Then the architects, engineers, contractors, and project management knows about it as well and would take appropriate action to correct it.
I would tend to agree with both of these posts. While my engineering specialty is in wood and not steel my job does require a good working knowledge of steel.The issue with SM is not rust in my opinion, but metal fatigue - It can manifest itself as tiny cracks around stress risers, or may be under the surface, requiring x-ray or eddy current detection. I would be willing to bet that a detailed fatigue analysis/investigation on this structure, even if it exists and is complete, probably makes certain lifetime assumptions regarding operating stresses and cycles that may or may not be correct or what is actually happening. MANY assumptions are made in these types of analyses, and they have to be verified and validated for the lifetime of the structure. I have been a structural engineer (Aerospace), for about 21 years now, so if I can contribute to the discussion, or answer any particular questions, feel free to ask away. I sent a resume to WDW but never got a response![]()
Metal fatigue would be my first concern as well. When any metal is continually loaded and unloaded it will begin to weaken. This loading and unloading can be pretty extreme in a roller coaster. A professional engineer is not going to touch this project unless there is no doubt in his/her mind that the supports are structural sound because as jmvd20 pointed out they can be held criminally liable in the event of a faliure. The way a PE will get that peace of mind is through inspections and testing.
They will typically start with a visual inspection and look for the obvious stuff like rounded out bolt holes, cracks, buckling, etc but if none of that is evident you have to start looking deeper using ultrasonic testing, magnetic particle inspection, and radiographic inspection to confirm that the steel is still up to spec. I simply can not imagine Disney not doing some combination of all of these methods on a regular basis on a steel coaster like SM. They would most certainly be done if a PE is putting his seal on the refurb work being done.
What I do see in the pictures does not really worry me all that much. I see a bad paint job and what would appear to be some minor surface corrosion. I have seen steel in much worse shape from an appearance standpoint test out just fine. Steel doesn't have to be pretty to work.
EDIT: All that being said I am still of the opinion that they should have completley gutted this attraction. Good enough is simply not the Disney way IMHO.