The Hidden Engine of Amusement Parks
Amusement parks are symbols of joy, excitement, and family fun. Guests typically associate them with bright lights, thrilling rides, and unforgettable memories. Yet beneath this public-facing magic lies a complex operational ecosystem—one that rivals the logistical sophistication of manufacturing plants and major heavy civil construction projects. In 2025, the U.S. amusement park industry generated more than $35 billion annually, a scale that underscores both the commercial importance and operational demands of these destinations.
To keep the rides running and the environment pristine, parks must constantly engage in construction, repair, and logistical coordination. This means that behind every roller coaster launch and firework finale is a fleet of forklifts, cranes, trucks, and maintenance crews working tirelessly to ensure that infrastructure is not only functional but also safe and efficient.
One iconic Florida amusement park, known worldwide for its immersive guest experience, recently faced a new and demanding construction challenge. A solution they selected to be part of the project, FODS Ground Protection Mats, proved to be a pivotal asset in maintaining operational efficiency while protecting the park’s critical back-of-house infrastructure.
Logistics Under Pressure
A High-Demand Environment
The project centered on a large-scale concrete repair and replacement program, requiring the delivery, staging, and movement of over 3,000 concrete masonry units (CNUs). These materials had to be stored in a dedicated laydown yard, with constant movement of heavy equipment transporting tools, blocks and other materials to active work zones.
The equipment roster included industrial forklifts and front-end loaders, both of which exert tremendous pressure on surfaces. Over time, repeated passes create ruts, destabilize soil, and cause unsafe working conditions for operators. These surface failures slow down progress and increase project costs through required remediation.
The Risks of Traditional Methods
Historically, amusement parks and all form of construction contractors have relied on plywood sheets or aggregate rock to stabilize temporary work zones. While serviceable in some contexts, these solutions are poorly suited for heavy-duty logistics:
- Plywood: Quickly deteriorates under the concentrated weight of forklifts, splintering, bowing, and creating safety hazards.
- Aggregate (rock): Provides limited stability but demands continuous grading and replenishment. At the project’s conclusion, rock must be removed at significant expense.
- Soil exposure: Without reinforcement, soil compaction and rutting create persistent hazards and extend project timelines.
For this Florida project, Edwards Concrete, a master Bomanite installer and respected contractor in Central Florida, Orlando area, recognized that traditional solutions were both inefficient and incompatible with the park’s high standards.
Deploying FODS Ground Protection Mats
Why Ground Protection Mats?
After evaluating alternatives, the project team selected FODS 4’x8’ Ground Protection Mats, an engineered high-density polyethylene (HDPE) panels with an integrated anti-slip traction profile, designed to provide heavy-duty, reusable ground reinforcement.
Key advantages included:
- Load Distribution
The mats spread concentrated forklift weight across a larger surface area, eliminating soil rutting and maintaining smooth navigation. - Superior Traction
With an engineered anti-slip surface, both operators and equipment maintained traction even in wet conditions, enhancing safety. - Rapid Deployment
Crews installed mats quickly to establish forklift lanes and staging areas, then repositioned them as needed to match shifting work priorities. - Durability
Unlike plywood, which has a service life measured in days, or thin plastic alternatives, FODS Ground Protection Mats are designed for years of repeated use in punishing environments. - Sustainability
Reusable and recyclable, the mats aligned with the park’s commitment to environmental responsibility and reduced waste compared to one-time-use materials.
From Setup to Daily Operations
The mats were strategically placed to form defined forklift lanes and staging zones in the high-traffic laydown yard. Using FODS interlocking connecting hardware, the design prevented movement under repeated turning movements and ensured stable alignment.
The creation of this working platform provided operators smoother driving conditions and safer equipment handling. One project lead, Jordan, noted that the mats “stabilized the work zone from the first day and eliminated concerns about ground degradation.”
In a high-intensity environment where forklifts moved thousands of pounds of material multiple times a day, this stability directly contributed to meeting schedule deadlines.
Performance Outcomes
The results of the deployment were measurable and decisive:
- Zero incidents: No reported safety issues or ground-related interruptions.
- No remediation costs: The underlying substrate remained intact, eliminating the need for post-project landscape or soil repair.
- Consistent productivity: Operators were able to maintain speed and efficiency throughout the project, keeping timelines intact.
- Material movement success: All 3,000 CNUs were staged, transported, and placed without delays caused by ground failure.
The mats’ performance directly translated into time and cost savings. Instead of halting work to repair ruts, replace plywood, or regrade aggregate, the project team remained focused on completing critical infrastructure upgrades.
Protecting Brand Reputation
For one of America’s best-known amusement parks, brand value extends well beyond the attractions themselves. Operational excellence must be invisible to guests—any disruptions in cleanliness, safety, or accessibility risk undermining the guest experience.
By using FODS Ground Protection Mats, the park ensured that critical construction logistics unfolded seamlessly, away from the public eye. While no guest ever saw the mats, they played a pivotal role in maintaining the operational integrity that supports the park’s reputation for excellence.
Why This Case Matters Beyond Amusement Parks
Although this project took place in a world-class entertainment setting, the lessons apply broadly across industries where logistics intersect with surface protection:
- Industrial Yards: Protecting pavement and soil under repeated forklift or truck movement.
- Construction Sites: Stabilizing access roads, staging areas, laydown yards and walkways.
- Municipal Infrastructure: Supporting temporary detours or material staging in urban environments.
- Energy Projects: Providing stable access routes for turbines, transformers, or heavy equipment.
The case demonstrates that when projects demand efficiency, safety, and cost control, reusable ground protection delivers superior long-term value.
FODS vs. Traditional Methods
This side-by-side evaluation reinforces why Edwards Concrete and the amusement park chose FODS: not just as a temporary fix, but as a strategic investment in operational reliability.
Broader Industry Trends
The adoption of advanced matting systems like FODS 4’ x 8’ Ground Protection Mats reflects a broader trend in construction and logistics toward:
- Sustainability: Reducing reliance on disposable materials such as rock and plywood.
- Cost Optimization: Prioritizing total cost of ownership over lowest upfront cost.
- Risk Management: Emphasizing safety and predictability in high-pressure environments.
With rising regulatory scrutiny on stormwater compliance, dust control, and construction site safety, engineered matting solutions are becoming increasingly central to project planning.
Lessons Learned
- Plan for Logistics Early
Integrating ground protection into project planning ensures uninterrupted operations. - Think Lifecycle, Not Upfront Cost
While plywood or rock may appear cheaper, their short lifespan drives up long-term expenses. - Prioritize Safety and Stability
Equipment operators work more efficiently when ground conditions are predictable and secure. - Protect Reputation Through Reliability
Guest-facing businesses in particular cannot afford back-of-house disruptions.
Conclusion
Every element or the project helps to provide a top-notch visitor experience at one of America's most famous amusement parks. The laydown yard's invisible stability was crucial to the successful completion of a concrete repair project, even though the public was unaware of it.
By using FODS 4' x 8' Ground Protection Mats, the park and Edwards Concrete were able to: By selecting FODS 4’ x 8’ Ground Protection Mats, Edwards Concrete and the park achieved:
- Efficient movement of 3,000 CNUs
- Zero safety incidents
- Elimination of soil remediation costs
- Consistent equipment performance
By doing this, the project team preserved the operational excellence that serves as the foundation for the park's reputation in addition to meeting technical goals.
The result is obvious: the magic continued because FODS maintained the logistics.
