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New report reveals cause of cracked support beam on Fury 325 roller coaster

The coaster was closed for over a month after a video showing the ride speeding past the cracked beam went viral.

CHARLOTTE, N.C. — The North Carolina Department of Labor released its report on what caused a crack in a support beam of the Fury 325 roller coaster at Carowinds last summer with investigators determining the break was caused by "unidirectional bending fatigue." 

Fury 325 was closed for over a month after a viral video showed a huge crack in one of the ride's support beams on June 30, 2023. While crews were replacing the beam, state inspectors found another area on the ride that needed repair, which led to further testing before the ride eventually reopened in August 2023. 

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Alfred Bessette, an NCDOT-certified welder with over 20 years of experience, said that flaw, known as a "weld indication" is a sign that the weld wasn't done correctly.

The final analysis was conducted by Applied Technical Solutions, a Georgia-based firm known for materials testing, metallurgy analysis and engineering consultation. Inspectors determined the crack happened along a weld that spread around the outside of the beam until it could no longer handle stresses applied by the coaster. 

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The location of the crack, at the toe — where two pieces of metal come together — accelerated the crack's spreading, according to inspectors. 

Carowinds said the coaster went through a series of tests, including an accelerometer test, which uses sensors to ensure the ride is safe and consistent. The ride was then operated for over 500 cycles before the Department of Labor conducted its final inspection and gave formal approval to reopen the ride in mid-August. 

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