All photos courtesy of Ensign Engineering and Land Surveying.
In 2023, Universal Studios Hollywood introduced Super Nintendo World to its park, which featured the notable addition of the Mario Kart™ ride. Immersing visitors in scenes inspired by the popular game, Mario Kart ride includes the simulation of a thrilling race through the clouds.
Ensign Engineering and Land Surveying, Inc., collaborated with Universal Creative, AECOM and KHS&S to engineer these expansive clouds, which were constructed by using cold-formed steel (CFS) stud framing and a thin layer of plaster.
The project received the Creative Detail — First Place honor in the 2024 CFSEI Awards presented by the Cold-Formed Steel Engineers Institute.
Mario Kart ride at Universal Studios Hollywood includes the simulation of a thrilling race through the clouds.
Ensign Engineering and Land Surveying’s goal was to create eye-catching cloud shapes. The firm’s solutions helped solve structural design challenges related to the ride’s curved and organic cloud shapes.
Curved CNC Plates
Ensign Engineering’s first attempt to capture the cloud shapes involved putting together curved CFS studs to shape the clouds. This proved difficult for accurate structural analysis due to the significant section removal needed to create the curved shapes.
After brainstorming solutions, the Ensign Engineering team developed an innovative approach: Cut CNC steel plates precisely to the cloud contours found in the project’s 3D model.
The firm created a mockup using this approach. The mockup allowed for an exact match to the desired aesthetic shapes. It also enabled easier and more accurate analysis using its SCIA 3D modeling software.
Ensign Engineering recommended using CNC machines to cut steel plate ribs to create the cloud “bubbles,” which follow the cloud contours found in the project’s 3D model. The first mockup is shown here.
Ensign Engineering designed connections and openings to allow for cold-formed steel (CFS) stud placement.
The above photo shows a top-down perspective of one of the cold-formed steel (CFS) platforms before adding the CNC “ribs” to define the cloud shape.
Since the initial plates and cantilevered stud platforms alone lacked adequate rigidity, Ensign Engineering added steel stud blocking within the platforms for reinforcement. The combination of CNC-cut plates acting as “ribs” and the blocking CFS studs enabled the cloud forms to be both structural and sculptural.
Fabricating the ribs and platforms was an intricate process done in coordination with KHS&S and Stud.IO. Using the 3D model, Ensign Engineering designed connections and openings to allow for stud placement. Stud.IO then prepared the programming to be used by a Howick machine to roll and cut the steel studs to specific lengths.
This collaborative process allowed for the construction of stunning, yet functional platforms that captured the essence of the Mario Kart clouds. Solving the technical challenges required extensive teamwork, engineering creativity and pushing fabrication boundaries. The result is a visually striking sculptural statement delivered through innovation.
Ensign Engineering’s design approach allowed for the construction of functional platforms that captured the essence of the Mario Kart clouds.
The Massive Central Cloud 7
While shaping the clouds was difficult, supporting the ride’s massive central cloud (dubbed Cloud 7) was an even greater structural puzzle.
With a minimal direct load path to foundations, Ensign Engineering “had to get creative,” the CFSEI article about the project says. The firm devised a plan to hang the upper portion from steel above, while supporting the lower section on the ground.
To hang the structure, the team designed a system of internal platforms and drop studs. The intricate upper cloud was essentially an elaborate hanging ceiling, suspended from vertical steel studs anchored above it. To meet seismic requirements, the team installed internal lateral bracing in both directions.
This innovative approach enabled constructing Cloud 7 without compromising its structural integrity.
Ensign Engineering and Land Surveying’s isometric drawing of Mario Kart ride Cloud 7. The ground-supported half is highlighted in blue, while the upper half that hangs from the ceiling is in white.
The upper half of the Cloud 7 of the Mario Kart ride under construction.
The Ensign Engineering and Land Surveying team’s sculptural work is a testament to the engineering of art and structural stability in tandem. Read the complete story and obtain the complete design diagrams for Ensign Engineering and Land Surveying’s 2024 CFSEI Creative Detail Award here.
Universal Studios Hollywood – Mario Kart Ride
First Place – 2024 CFSEI Creative Detail Award
Winner: Ensign Engineering and Land Surveying
Tammy Gleed (left), P.E., 2024-25 CFSEI vice chair, and Dana Hennis (right), P.E., 2024-25 CFSEI chair, present the 2024 CFSEI Creative Detail First Place Award to Tye Carlile, P.E., Ensign Engineering, at the 2024 CFSEI Expo.
Project
Universal Studios Hollywood – Mario Kart Ride
100 Universal City Plaza
Universal City, CA 91608
Completion Date
January 2023People
Owner
Universal StudiosArchitect of Record
Rajan Prakash Pradhan, Universal CreativeEngineer of Record for Structural Work
Annie Fan, MSSE, P.E., AECOMCold-Formed Steel Specialty Engineer
Tye M. Carlile, P.E., Ensign Engineering and Land SurveyingCold-Formed Steel Specialty Contractor
Shane Hastain, P.E., KHS&S
Additional Resources