AN ABSTRACT OF THE THESIS OF Joel Hartter for the degree of Master of Science in Forest Engineering presented on April 21, 2004. Title: Investigation of Synthetic Rope End Connections and Terminations in Timber Harvesting Applications Abstract approved: John J. Garland Steel wire rope is the accepted standard in logging. It is strong, durable, stiff, and dependable in the logger’s arsenal. However, steel wire rope has several disadvantages: its strength to weight ratio is low; it is difficult and time-consuming to splice; and used wire ropes contain jaggers. Ultra-high molecular weight polyethylene (UHMW-PE) braided rope has potential to replace steel wire rope. The offshore mooring and shipping industries have appreciated it for years. Characteristics such as a specific gravity less than one (it floats!), high flexibility, low stretch, and ease of splicing make the synthetic rope useful. At equivalent diameters, synthetic rope has an equal or greater breaking strength to that of steel wire rope, but at 1/7 the weight. This thesis is an investigation of the end connectors for the unique physical, mechanical, and thermal properties of UHMW-PE 12-strand braided rope that make this technology of interest in logging applications. This studied focused on three diameter classes of the synthetic rope that are common to logging operations: 3/8”, 9/16”, and 5/8”. Within each diameter class there were five different spools representing separate production runs. A randomized complete block design was used with each diameter class and the corresponding five spools a separate population. Following the laboratory tests, the breaking strengths were compared to the buried eye splice. Three types of end connectors were evaluated during this pilot study. They are identified as spliced, adhesives, and dry hardware. Spliced end connections provided consistent performance in breaking strengths. The end connections with adhesives had variable strength performance laboratory tests and are therefore not recommended. Within the dry hardware end connections, the pinned nubbin and knuckle link provided the highest breaking strength relative to the buried eye splice. This project has accomplished its objectives. It was the first extensive study on end connections specifically designed for synthetic rope. New end connections were developed and steel wire rope connections were modified to meet the strength and usability criteria for timber harvesting operations. Suitable end connections for forest operations were: buried eye splice, Whoopie Sling, long splice, rope clamps, knuckle link, pinned nubbin, and Y-splice. These end connections suitable for use with forest operations were identified and recommended user guidelines were given. Further research and development needs to be conducted on these seven concepts with larger sample sizes and in varied conditions. ©Copyright by Joel Hartter April 21, 2004 All Rights Reserved Investigation of Synthetic Rope End Connections and Terminations in Timber Harvesting Applications by Joel N. Hartter A THESIS submitted to Oregon State University in partial fulfillment of the requirements for the degree of Master of Science Presented April 21, 2004 Commencement June 2004 Master of Science thesis of Joel N. Hartter presented on April 21, 2004. APPROVED: Major Professor, representing Forest Engineering Head of the Forest Engineering Department Dean of the Graduate School I understand that my thesis will become part of the permanent collection of Oregon State University libraries. My signature below authorizes release of my thesis to any reader upon request. Joel N. Hartter, Author i ACKNOWLEDGEMENTS I would like to express my deepest thanks to my major professor, Dr. John J. Garland. He has supported my efforts here at Oregon State University in so many different ways. From the day I arrived, he has helped me in my transition into the forestry sector. He has given selflessly of his time and energy and I thank him sincerely for his many contributions, support, and encouragement during my time at OSU. I would also like to express my heartfelt appreciation to my committee members that have spent countless hours discussing the project, laying out the study design, and reviewing my work. Their contribution and critical evaluation has been invaluable. Thanks to Dr. Kevin Boston, with whom I spent many hours in his office laboring over statistics and study design. Thanks so much for your patience and confidence in me. Dr. William “Skip” Rochefort was a great asset on this project. Using his expertise in polymers, he patiently answered my questions. John Sessions provided invaluable engineering advice on this project. I would also like to extend thanks to Dr. William Huber for serving as Graduate Representative on my committee. To all of them, thanks for leaving your doors open to discuss the project. I wish to recognize Oregon Occupational Safety and Health Administration for providing funding through the Worksite Redesign Grant. Chuck Smith, Dave Strauss, Rafael Chou, and Danielle Stenvers of Samson Rope Technologies were instrumental in completing this project. Along with Paul Smeets of Dutch State Mines (DSM), I thank them for their cooperation in providing product and information. Additionally, I want to recognize the contribution of Phillystran, Inc., 3M Corporation, DSM, and Samson Rope Technologies for supplying their products, services, and expertise. In addition, I would like to extend my sincere gratitude for many others that helped bring this project and thesis to a reality. As an active member on the Synthetic Rope Research Team, Steve Pilkerton assisted in laboratory tests, helped prepare test samples, and encouraged my success in the project in many ways. Milo Clausson was my “ace in the hole” when it came to setting up and assisting me with the laboratory testing. Thanks to David LaFever for his skillful fabrication of my end connections. I ii wish to thank Jared Leonard for his patience in training a very “green” forest engineering student. Heartfelt thanks goes to Hamish Marshall for his advice and willingness and interest to solve all kinds of problems, especially those relating to blue rope. Thanks also to John Hunt and Kevin Harris for their help with all my chemical engineering needs. Finally, I wish to express my deepest gratitude to my wife Rachel who has encouraged me these past two years in countless ways. She has been extremely patient during the weeks of long study hours; she has given support and a listening ear in times of frustration; and she has shared in all of the joy that I have experienced here. I am so thankful for her challenging me to search for answers. For all of this and so much more, I am truly indebted to her. iii TABLE OF CONTENTS Page 1 Introduction................................................................................................................. 1 1.1 Background......................................................................................................... 1 1.2 Research Problem............................................................................................... 2 1.3 Research Questions............................................................................................. 2 1.4 Hypothesis........................................................................................................... 3 1.5 Research Objectives............................................................................................ 3 1.5.1 Objective 1 .................................................................................................. 4 1.5.2 Objective 2 .................................................................................................. 4 1.5.3 Objective 3 .................................................................................................. 4 2 Literature Review........................................................................................................5 2.1 Introduction......................................................................................................... 5 2.2 History of Synthetic Rope................................................................................... 5 2.3 UHMW-PE Fiber and Rope Production ............................................................. 7 2.4 Synthetic rope Use in Other Applications ........................................................ 10 2.5 Synthetic Rope Research in Forestry................................................................ 10 2.6 Synthetic Rope Research at Oregon State University....................................... 11 2.7 Research in End Connections for Synthetic Rope For Timber Harvesting Applications ...................................................................................................... 13 2.7.1 Knots ......................................................................................................... 13 2.7.2 Splices ....................................................................................................... 14 2.7.3 Drum Attachments .................................................................................... 15 2.7.4 Compression Fittings................................................................................ 15 2.7.5 Epoxies...................................................................................................... 16 2.7.6 Shackles and Eye Splices.......................................................................... 16 2.8 Test Standards..................................................................................................