TRUBLUE zipSTOP Zip Line Brake Systems

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A good zip line brake should do more than stop the rider.

It should work with the speed, slope, rider weight range, landing area, trolley, operating procedures, and overall design of the zip line.

Challenge Design Innovations designs and builds commercial zip lines using the TRUBLUE zipSTOP® Zip Line Brake, "a self-regulating magnetic braking system" designed to provide smooth, consistent rider deceleration.

CDI is a TRUBLUE zipSTOP Preferred Installer.

Whether you are planning a new zip line, upgrading an existing attraction, or replacing another braking system, CDI can help you evaluate the complete system and determine whether zipSTOP is the right solution.

What Is the zipSTOP Zip Line Brake?

zipSTOP is an zip line braking system that uses eddy current magnetic braking technology to slow riders as they reach the end of a zip line.

Instead of relying on the rider to brake themselves, the zipSTOP braking trolley engages the rider's trolley and begins slowing the rider automatically.

The system adjusts braking based on the rider entering the brake, helping create a controlled and consistent deceleration across a wide range of rider weights and arrival speeds.

For operators, that means the braking system can handle much of the work that would otherwise depend on participant action or guide timing.

Magnetic braking instead of friction braking

The technology inside zipSTOP uses magnets and eddy currents to create braking resistance.

There are no brake pads creating the primary braking force.

As the device operates, conductive components move through a magnetic field. The resulting eddy currents create resistance that slows the system. The braking force responds to the speed of the device, helping provide controlled deceleration.

For zip line operators, this technology provides several advantages:

  • Smooth rider deceleration
  • Consistent braking across different rider weights
  • Reduced dependence on participant braking
  • Automatic resetting after each rider
  • Less friction-related internal wear
  • Reliable performance in outdoor operating environments

But the brake is only one part of the system.

The zip line itself still has to be designed correctly.

Designing a Zip Line Around zipSTOP

Installing a zipSTOP is not as simple as adding a device at the end of any cable.

Arrival speed, cable slope, rider weight, braking distance, landing platform configuration, trolley selection, reduction ratio, and backup braking all need to work together.

That is where CDI comes in.

We look at the whole zip line

When we design a new zip line around zipSTOP, we evaluate factors including:

  • Zip line length
  • Elevation changes
  • Cable tension and sag
  • Expected rider speeds
  • Rider weight range
  • Primary braking distance
  • Landing platform size
  • Brake trolley location
  • Reduction line configuration
  • Rider trolley selection
  • Emergency braking
  • Guide positioning
  • Rescue considerations
  • Daily operations

Our goal is not simply to make the zipSTOP fit.

Our goal is to create a complete zip line system where the brake, cable, trolley, platform, rider, and operating procedures work together.

How Fast Can a zipSTOP Handle?

The standard zipSTOP can accommodate different arrival speeds depending on how the braking system is configured.

TRUBLUE currently rates the original zipSTOP for riders from 33 to 330 pounds.

With a direct 1:1 configuration, the device is rated for speeds up to approximately 22 mph. With an appropriate 2:1 reduction line configuration, it can accommodate arrival speeds up to approximately 37 mph.

That does not mean every zip line traveling below those speeds is automatically appropriate for the system.

Braking distance, rider weight, line geometry, reduction configuration, and other factors still need to be evaluated.

For faster zip lines or different configurations, TRUBLUE also manufactures other zipSTOP models, including the zipSTOP IR and zipSTOP SPEED. The SPEED model is designed for higher arrival speeds than the standard zipSTOP.

CDI can help determine which configuration makes sense before equipment is purchased or the zip line is built.

A Passive Braking System for Riders

One of the major differences between zipSTOP and traditional hand braking is that the rider does not need to control their own primary stop.

With participant hand braking, riders may be instructed to place a gloved hand on the cable behind their trolley and increase pressure to slow themselves.

That approach can work well on appropriately designed systems, but it requires the participant to understand the instructions and react correctly.

zipSTOP takes a different approach.

The brake engages automatically as the rider reaches the braking zone.

Less dependence on rider reaction

A first-time participant may arrive at the landing platform excited, distracted, nervous, or simply focused on the ride.

An automatic braking system reduces the amount of braking responsibility for that person.

That can be particularly useful for commercial zip lines serving large numbers of participants with different experience levels.

The rider still needs to follow operating instructions, but stopping the zip line is no longer dependent primarily on that rider correctly applying a hand brake.

Consistent Braking for Different Rider Weights

A common zip line design challenge is the difference between a lighter rider and a heavier rider.

They may travel differently down the same cable.

Their arrival speeds can differ.

And a braking system still has to work across the permitted participant range.

TRUBLUE designed the zipSTOP's self-regulating braking technology to help equalize deceleration across different rider weights.

That does not eliminate the need for proper design and system testing.

But it gives designers another tool for creating a braking system that accommodates a broad range of participants.

zipSTOP Automatically Resets

Once a rider has completed the braking cycle, zipSTOP retracts and resets the braking line for the next participant.

TRUBLUE identifies automatic reset as one of the system's main operational benefits.

That can be valuable for commercial operations where staff are repeatedly cycling riders through the same attraction.

Instead of manually rebuilding or repositioning the primary braking system after every participant, the device returns to its ready position.

Course design and operational procedures still need to account for confirming that the braking system has properly reset before another rider is sent.

Every zipSTOP System Still Needs a Backup Brake

This is important.

zipSTOP should not be treated as the only braking component protecting the rider.

TRUBLUE specifies that a complete zipSTOP braking system requires an independent emergency arrest device, often called an EAD, emergency brake, or backup brake.

The purpose of the backup brake is to provide another means of arresting the rider if the primary braking system does not operate as intended.

When CDI designs a zip line using zipSTOP, we look at both:

Primary braking: The zipSTOP system that normally slows the rider.

Emergency braking: An independent system intended to arrest the rider if the primary brake is not available or does not perform as expected.

The landing area needs enough space for the complete braking system, not simply the zipSTOP device itself.

That is one reason brake selection should happen early in the zip line design process.

Can You Retrofit an Existing Zip Line With zipSTOP?

Potentially.

An existing zip line may be a candidate for conversion to a zipSTOP braking system, but it needs to be evaluated first.

We may need to look at:

  • Current arrival speeds
  • Cable slope
  • Participant weight limits
  • Landing platform length
  • Existing brake system
  • Rider trolleys
  • Available braking distance
  • Structural attachment points
  • Emergency brake
  • Guide positioning
  • Operational procedures

Sometimes the existing zip line can accommodate a zipSTOP with relatively limited modifications.

Other installations may require changes to the landing platform, braking zone, cable configuration, trolley system, or other components.

CDI can inspect the existing system and help determine what is practical before you invest in new equipment.

zipSTOP Maintenance and Annual Service

zipSTOP is a life-safety device and needs to be inspected, maintained, and serviced according to manufacturer requirements.

TRUBLUE requires annual service for zipSTOP devices to maintain compliance with its service requirements and warranty conditions. Annual service includes inspection and testing of the device and its braking line components. You will need to ship the unit in to TruBlue for inspection and service.

Operators also need to perform the routine inspections and maintenance required by the manufacturer's current operating manual.

CDI can help operators understand how the zipSTOP fits into the larger inspection and maintenance program for the entire zip line.

That includes more than the brake.

Your cables, structures, platforms, trolleys, attachments, backup brake, equipment, and other components also require regular inspection and maintenance.

Why Work With CDI on a zipSTOP Project?

Challenge Design Innovations has been designing and building challenge courses and zip lines for more than 45 years.

We do much more than install braking equipment.

CDI can provide:

  • Site evaluation
  • Zip line feasibility
  • Concept development
  • Zip line design
  • Engineering
  • zipSTOP system integration
  • Construction
  • Brake installation
  • Landing platform design
  • Equipment selection
  • Operational training
  • Professional inspections
  • Maintenance
  • Repairs
  • Existing zip line upgrades

And CDI is specifically listed by TRUBLUE as a zipSTOP Preferred Installer.

That means you are working with a company that understands both the braking equipment and the larger zip line system around it.


Frequently Asked Questions About zipSTOP

Is zipSTOP an automatic zip line brake?

zipSTOP is a passive automatic braking system. The rider does not need to manually activate the primary brake. The braking trolley engages the incoming rider and the zipSTOP device controls the deceleration.

Does zipSTOP use friction to stop riders?

Its primary braking technology uses eddy current magnetic braking rather than traditional friction brake pads. TRUBLUE uses moving conductive components and magnets to generate braking resistance.

What rider weights can use the standard zipSTOP?

TRUBLUE lists a rated working capacity of approximately 33 to 330 pounds, or 15 to 150 kilograms, for the standard zipSTOP.

The complete zip line may have different participant restrictions based on its design, equipment, operating procedures, and other factors.

What is the maximum speed for a zipSTOP?

The standard zipSTOP can be configured for rated working velocities up to approximately 37 mph when used with the appropriate 2:1 reduction system. Direct 1:1 configurations have lower rated speeds.

If your riders are expected to arrive faster, another zipSTOP model or a different design may be required.

Does zipSTOP eliminate the need for a backup brake?

No.

TRUBLUE requires an independent emergency arrest device as part of a complete zipSTOP braking system.

CDI considers both the primary and backup braking systems when designing or modifying a zip line.

Can zipSTOP be added to an existing zip line?

Sometimes.

The existing line first needs to be evaluated for speed, braking distance, structural configuration, landing platform space, trolleys, and other design factors.

CDI can assess the system and determine what changes would be necessary.

Does zipSTOP need annual servicing?

Yes. TRUBLUE requires annual service for zipSTOP devices. Operators also need to follow the manufacturer's current inspection, maintenance, and service requirements.

Which zipSTOP model do I need?

That depends on your expected arrival speed, rider weight range, braking distance, zip line configuration, and other design factors.

The standard zipSTOP, zipSTOP IR, and zipSTOP SPEED are designed for different applications.

CDI can help determine the appropriate system as part of the overall zip line design.

Now What?

Challenge Design Innovations can help you design the complete system around the TRUBLUE zipSTOP Zip Line Brake, whether you are building a new attraction or upgrading an existing zip line.

Tell us about your zip line project, and we can help determine whether zipSTOP is the right braking system for it.