Aerial Adventure Course Design

Hubbard Merrell Engineering started working on Aerial Adventure Courses in 2010. After 5 years offering structural engineering services to manufacturers and installers, Hubbard Merrell Engineering further developed our Adventure Course Department with the addition of a subject matter expert as our department leader. We are now able to offer operational support for designs as a system integrator. We review, develop, and analyze operation manuals to accompany our structural drawing and calculations.

Our Aerial Adventure Course department also includes professional structural engineers registered in 26 states, and counting, as well as design and documentation support staff.

Our services include providing cost effective structural engineering for Aerial Adventure Courses including Zip Lines and to be a widely used resource for the most current government regulation information available in the United States.

zipDesignIn additional to our structural engineering services, Hubbard Merrell Engineering has developed and operates is a revolutionary tool that allows you to easily and quickly simulate and optimize your zip line system.

Completed Projects
Registered States

What We Do

Aerial Adventure Course Design Services

Structural Engineering/Design
Reverse Engineering

Structural Inspections
Commissioning/Acceptance Inspections


Coordination during
Design and Construction

AutoCAD Generated Drawings
Revit Generated Drawings

Operational Audits and Inspections
Operation Manual Development

Meet Our Team

AAC Design Team at Hubbard Merrell Engineering


Micah Henderson works as the Aerial Adventure Course department manager for Hubbard Merrell Engineering in Flagstaff, AZ. Micah started working in the Aerial Adventure Course industry in 1998 and has expertise in course design, installation, inspection, operation, operator training and development of operation manuals. Micah contributes to the Aerial Adventure Course industry through her volunteer roles on the Board of Directors for the Association for Challenge Course Technology (ACCT) and the Secretary for the ASTM F2959 Standard task group for Aerial Adventure Courses.



Dave is a Principal / Owner with Hubbard Merrell Engineering. Dave is responsible for structural engineering design and management from start of design to end of construction. Individual engineering services and responsibilities include; preliminary structural systems design, project design, project review, and coordination of structural engineering services provided by Hubbard Merrell Engineering.

Dave’s experience in the Aerial Adventure Course industry goes back to when he worked as a guide at a summer camp as a teenager. He has been designing courses professionally since 2010. Dave has worked on approximately 60 projects across the industry, including; zip line tours, aerial adventure parks, challenge courses, and climbing structures. Dave’s understanding of the available Standards and typical operation of the elements has led to the overall success on these projects.



Michael is a structural designer for Hubbard Merrell Engineering who specializes in Aerial Adventure Course structures. He has received his certification as an Engineer in Training (E.I.T) and has assisted in designing multiple Aerial Adventure Courses since he started with Hubbard Merrell Engineering in 2016. He received a degree in Mechanical Engineering from Northern Arizona University.


Our Clients
  • "Hubbard Merrell was just the team we needed for our last zip line project. Not only do they know the ins-and-outs of zip lines and their associated equipment, they also have a mastery of the applicable federal and state regulations. When we have a challenging job with challenging regulatory requirements, teaming up with Hubbard Merrell is an easy and smart decision. We thank them for always being professional, pleasant, and punctual. We look forward to working with them again in the future!"

    Nick Redinger
    Challenge Works
  • "The fact that Hubbard-Merrell employs both engineering professionals and Aerial Adventure industry professionals, giving them the ability to support both the structural and operational aspects of a project, is one of the many reasons we have appreciated working with them."

    Leslie Sohl, MS
    Bonsai Design, LLC
  • "At Flagstaff Extreme, we try to use local business expertise. Flagstaff Extreme is located in the same City as Hubbard Merrell and recently we expanded our offering to include 3 adventure zip courses at the largest County Park in Arizona.  Through collaboration between our team, Hubbard Merrell, and the County, we were able to improve upon the process we originally experienced with our initial installation in 2011. When we engaged Hubbard Merrell and specifically Micah Henderson and her team to provide the necessary engineering details and documentation, they delivered within a tight budget. The build was completed ahead of schedule and the team at Hubbard Merrell was able to complete their final inspection in a timely manner, allowing us to get our final approvals from the County and open to the Public.  We appreciate the flexibility and communication that is somewhat rare in this day and age."

    Paul Kent
    Flagstaff Extreme, LLC
  • "My experience working with Hubbard Merrell has been a pleasant and efficient process. Their depth of expertise in the adventure industry sets them apart from other engineering firms I have worked with in the past. The Hubbard Merrell team effectively translated our goals and desired outcomes into a specific structural design. They serve as a bridge between the traditional spirit of Adventure Programming and the increasingly complex world of challenge course standards. Their attention to detail and ability to consult on industry specific issues has been an asset to Project Adventure and my work as the installation service director."

    Matt Loy
    Project Adventure Inc.
  • "Working with Hubbard Merrell, specifically Micah Henderson, has been a fantastic experience. Whether addressing technical design work or simply consultative work surrounding our Challenge Course program, the team at Hubbard Merrell has been an asset to Young Life as we continue to seek to raise the bar in our professionalism and safety standards. Hubbard Merrell adds value to our programs."

    Brian Spindor
    Young Life Camping
  • "We have worked with a number of different engineering firms in our history and regard Hubbard Merrell as professional friends. Open communications, attention to detail and ethical practice are the attributes we have found as the hallmark of Hubbard Merrell."

    Mark Glynn, P.E.
    Principal- Glynn Geotechnical Engineering
  • "Outplay Adventures LLC recently partnered with Hubbard Merrell to construct the TreeTop Adventure Park at Snow King in Jackson WY. The Team at Hubbard Merrell went above and beyond our expectations in coordinating our project, within our project budget, to meet the very precise requirements of the USFS. From Design, Construction and Operational requirements, the Team at Hubbard Merrell was instrumental in helping Outplay Adventures adhere to the ASTM Standards, as required by USFS, in completing the project at Snow King. There is no doubt that we will utilize the talents of the Hubbard Merrell Engineering Team wherever possible in our future builds."

    Dave Johnson
    President- Outplay Adventures LLC.
  • "ABEE Inc., in conjunction with Hubbard Merrell Engineering, has designed and built Big Zip Tours, Aerial Adventure Parks, Large Climbing Towers and Ropes Courses. Hubbard Merrell Engineering is a company with passionate, knowledgeable employees who have a firm understanding of the Challenge Course and Zip Line Industry. Their engineering expertise and contributions to building projects has been incomparable."

    Ryan Olson
    Owner - ABEE Inc.