ZIPLINE DESIGN AND CONSTRUCTION

A Briteway Corporation (ABC)

Home About Zipline Design & Construction
  • Captain Zipline Tour  is seeking opportunities to design and build new zipline tours, zipline canopy tours, and aerial adventure parks.  With more than 30 years of construction experience, creative problem solving, and knowledge of the tourism industry.   Zipline construction in the U.S. dictates a higher standard than in many other jurisdictions.  We specialize in developing courses using engineered poles and rock anchors in difficult terrain and have devised systems that cause minimal environmental disruption.  Interested in building a course in the trees, no problem.  We have working relationships with a number of canopy tour and tree house builders who specialize in the nuances of canopy construction and anchoring to trees.

INSTALLING ZIPLINE CABLES & ANCHORS

  • Excavation, with careful supervision, can make short work on difficult terrain. Attachments for pouring concrete in remote locations make this equipment invaluable.
  • Eco tours, by definition, dictate minimal site disturbance. Well-executed digging and backfilling efforts will be rewarded with minimal fine-grading work.
  • Wes, aka, “Mr. Track Hoe,” has been taming Mother Earth for 20 years. And his company will travel for zip line projects in Colorado and the Rocky Mountain Region.
  • Steel pipe is used for industrial strength applications like zipline construction. A one-time expense that will last more than 25 years–with proper concrete foundation systems–steel poles are heavy and require specialized certified welding detailing.
  • A pair of pipe suppliers helped find some steel zipline pipe made in the USA. Don’t settle for any foreign pipe, clamps or other critical items
  • Another worker bee in the chain from raw material to completed zip line tour. Building this Colorado zip line involved many, many construction man-hours.
  • Planting the zip line poles in inaccessible locations and minimizing eco-site disruption requires hand digging, forming and pouring concrete. All materials need to be delivered to the pole locations by people or donkeys!
  • Over 400 pounds of redi-mix concrete goes into each hole. The poles need bracing and the concrete should cure for 3 weeks before any cable tension is applied.
  • Rock bolts and rock anchors are drilled at least 24 inches into solid rock and tested for pullout resistance with a dynamometer. Adjacent trees and flora should be preserved and protected from damage.
  • Certified welders don’t come cheaply! Welding zip line poles in remote locations necessitates long welding leads and 4WD capabilities.
  • Zip line Tour infrastructure includes storage for gear and a “guide shack” for weather protection and staging areas. Camouflage these structures to maximize aesthetics along the zip line tour.
  • All systems “go” as Captain Zipline prepares to test the first cable ride. Who says you need to use a test dummy? We have a “live dummy.”

INSTALLING ZIPLINE CABLES & ANCHORS

  • Construction specs, cable details, and design criteria are provided for a fee during the feasibility study phase of any commercial zipline project. Captain Zipline subcontracts each specialty phase of a zipline tour project to experienced engineers and excavators, and we build the zipline system “in house.” Qualified tradesmen in most areas of the USA can be assembled for work on the customer’s jobsite locations.
  • The ½” galvanized cable is heavier than a ton of bricks in multi-thousand foot lengths. Get these fellas a forklift and be careful not to kink, nick or mutilate that zipline cable. Breaking strength 23,000 lbs.
  • Every cable job needs a “cable guy” and we have him! Cable is only readily accessible on a cable trailer. Plan for some rough trailer use, and don’t forget that 4WD ATV with a winch!
  • Anchoring zip line poles takes time, men and machines, and money. The anchor rods and bolts must be secured, buried in earth or rock. And don’t forget lightning rod systems.
  • Anchors must be 7-8 feet in compacted, undisturbed terra firma. It’s a dusty, difficult job with a pneumatic tamper man.
  • Using a dynamometer to measure anchor stability at 6,000 lbs. or more pullout resistance is necessary.
  • Rock anchors and post bases require engineering, reinforcing, and concrete forming.
  • Cable tensioning to required cable tension requires fine tuning on a grand scale. This happens with a “zipline cable crew” of several workers and equipment. Annual inspections of cable tension and guy wire condition are conducted using a “tensiometer.”
  • More cable “tuning” with specialized tools and experienced subcontractors.
  • Looking down Gunbarrel zip line run. Cable clamps were upgraded and high strength guy “wire rope” cable was added to upgrade the anchor system to 15,000 lbs. breaking strength per anchor guy.

Inquiries for zipline tour and aerial adventure park construction and consultation