Red Gold

[animated graphic of helicopter doing touch and go]

[Rotor & Wing International Magazine]

Mining The Northwest's Red Gold

by Mary Lou Harrsch - January 1978

Rising out of an emerald-clad gorge in the Siuslaw National Forest's Siletz River Valley, a Pacific Helicopters' Hiller UH-12E-J3 Soloy Conversion with Bill Reed at the stick maneuvers between two weathered 150-foot snags to deliver a 1,200-pound payload of red gold to an eager crew clustered at the landing.

Red gold?

That's the object of attention as the gold mining scene above is repeated, in one form or another, hundreds of times a day throughout the Pacific Northwest. What has happened is that helicopter operators have jumped onto the skyrocketing demand from the roofing industry for cedar shades (shingles) and have found red gold laying on the forest floor.

Western red cedar (Thuja plicata) once thrived in the moist coastal climate of Oregon, Washington, and British Columbia, primarily at elevations below 4,000 feet. Today large quantities of cedar are laying on the ground, victim of the rush to extract Douglas fir. Thirty years ago, Northwest loggers cut down the less valuable cedar to provide a cushion for falling fir trees. This cedar "pillow" prevented the brittle firs from breaking on impact.

Over the years, the fallen cedars have remained where they were dropped and stayed largely immune to the weathering effect of time and pests. Unlike other species, cedar does not succumb readily to beetles, moisture, or rot although as the seasons passed many of the trees were buried under the falling needles of their living brethern.

When cedar shakes became more and more popular as roofing material because of their durability, loggers began scouring the hillsides for the forgotten species. [ground crew on helicopter logging job]

After locating a unit, a timber cruiser would appraise the find and offer a stumpage fee for salvage rights. Teams of cutters would then be sent in to buck the logs into 10- to 40-foot (three- to 12-m) lengths. The logs were then dragged across the ground by a yarder system of cables and pulleys to a landing where they were bucked into 24-inch (61-cm) lengths and split into bolts with a mall and wedge.At the mill the bolts were split again and beveled by band saw.

Cedars take off

With the introduction of helicopters to this area only a few years ago, the yarder system was eliminated and the cedar bolt industry launched to new heights of production. The logs are now bucked into 24-inch (61-cm) lengths at the site and further split into bolts. The bolts are slung into 1,200-pound (540-kg) bundles that are hooked by the helicopter and delivered to the landing.

Today, the cedar bolt industry is employing a host of operators with small piston and turbine helicopters. Red gold is being mined with Bell 47s, Aerospatiale Alouettes, Hiller 12s, and even Bell JetRangers.

Joe Anderson's Pacific Helicopters Inc., based near Salem, Ore., has tapped this new market for its three Hiller UH-12-J3 Soloy Conversions. Anderson provides his aircraft, pilot, mechanic, assistant mechanic, and support truck to the logging company for $225 an hour.

With an average 1,200-pound (540-kg) payload, one of Anderson's Soloy Conversions consumes 24 to 27 gallons (83 to 90 l) of fuel per hour. Under average weather condiitons and terrain and with a 50- to 75-foot (15- to 22-m) line, he reported that it can deliver 10 to 12 cords of cedar per hour.

Under ideal conditions with landings just behond tossing distance, production can be doubled. "I have delivered 67 cords in three hours," related Joe Anderson, "but that is the exception rather than the rule."

"In difficult terrain with a lot of old snags, it is sometimes necessary to use a 100-to 150-foot line or longer," explained pilot Dan Cobb. "Then your production drops because of the maneuvering required to thread that line down to the hookers who are more difficult to see. I have flown with a 250-foot lead, but you could barely pick out the hookers from that altitude.

(It would probably be a good idea to point out to the uninitiated that a "hooker," in logging circles, is athe person who hooks up the logs to the helicopter or yarder system.)

"Cedar can be deceiving in moisture content," Anderson added. "We must use an onboard weighing system to regulate the load bundles. Also the steep slopes make it more difficult for the ground crews to accurately judge their loads."

"Snags are one of the primary hazards to the helicopter, since they stick up from 150 to 250 feet," he observed. "With an engine failure you wouldn't have anyplace to set down in the heavy timber, but we have never had an engine failure with the Soloy Conversion."

Anderson purchased his first J3 Hiller two years ago and followed it with two more in May 1977.

"I have always been partial to Hillers," he admitted. "They have proven to be a reliable workship. With the turbine conversion, we have experienced not only more power but also a 70 percent maintenance cost savings. Our first ship now has over 960 hours without any unscheduled maintenance."

"With our turbine, we can operate at maximum gross weight constantly regardless of altitude or temperature. Our average operationa cost is only $125 an hour, compared to over $170 an hour with our old recip. I would attribute most of our savings to maintenance. With over 900 hours per machine per year, we are also benefitting from

a seven percent insurance rate compared to the average of eight or nine percent," said Anderson.

He attributes much of his success in cedar logging to his experienced pilots. Chief Pilot Bill Reed has logged over 1,000 hours in Hillers with 400 of those in the Soloy machine. Thirteen year Marine Corps veteran Dan Cobb has spent over 1,500 of his 5,000 hours in the logging industry, principally In the big tandem rotor Boeing Vertol helicopters.

Anderson's customers Include J&W Shake Co. and Pacific Cedar Logging, the principal cedar salvager working the Boise Cascade timberlands. Bull Buck (logging boss) Joe Hatfield is exuberant over the utilization of helicopters in his operation.

Cash in cords

"Helicopters have greatly reduced the back breaking physical labor involved in cedar bolt operations and multiplied production," Hatfield said. "I figured my time and labor costs for the conventional yarder method at about $55 per cord. Compare that to only $22 per cord for the helicopter. We average about 70 cords in a 6 ½ hour work day."

Pacific Cedar markets the bolts to J&W Shake Co, for $210 to $230 per cord in the Olympia/Vancouver area. Paying low Oregon stumpages of only $25 to $60 per cord, depending on quality and density, with cutters averaging $70 to $80 per cord on a piecework basis, Pacific Cedar Logging enjoys a comfortable profit margin without massive equipment investment.

Wind, rain, and coastal fog are primary deterrents to daily operations, with fire hazard a major consideration during the summer fire season. "We had only 14 downdays this year due to fire hazard," recalled pilot Dan Cobb, "and during that time we were available for fire suppression."

"Without the friction created by a cable yarder operation, the fire potential is much less," explained Joe Hatfield. "Aerial cedar operators are frequently allowed to continue operations when conventional logging is stopped. Closures depend on the fire restrictions imposed by each individual district, with overall supervision by the state."

"Sometimes, partial restrictions are imposed," added Cobb. "For instance, there is a procedure called hoot owling under which we can only operate until noon."

Over the ridge in Lincoln City, we find the Oregon Coast's largest shake mill, Weathershed Inc. Opened only a year ago, Weathershed is an offshoot of Supreme Cedar, in Concrete, Wash. Weathershed's two Soloy Conversions feed four bandsaws producing shakes for a hungry California market by salvaging most of Georgia Pacific's felled cedar.

Saving the regrowth

"Conventional yarder operations were tearing up so much of the regrowth, which is a lumber company's real asset, that it was getting to the point where many large companies just didn't want them working their stands," reflected General Manager Loren Lindstrom. "The introduction of helicopters solved this environmental problem as well as increasing production from only 10 cords per day to over 100 cords per day. [map of Pacific Northwest with cedar groves indicated]

[map of Pacific Northwest with cedar groves indicated]

"Of course, there were a few outfits that would come in and hack out a landing pad the size of a football field. They were giving the industry a bad name, but they didn't last long," he added. "We land in the road, if necessary, and try to trim back as little area as possible for the hookers. Our philosophy is: 'Nothing evergreen ever falls in a professional cedar bolt operation."

"It is also important when falling an occasional cedar snag to fall it longitudinally rather than across the sidehill where it may roll down, crushing the regrowth. The lumber companies frequently send out woods supervisors to observe the cedar bolt operations to insure conservation practices.

"What I'm really trying to say is, a cedar bolt operator has to know what he's doing if we're going to maintain a favorable image in the lumber industry," Lindstrom emphasized. [picture of helicopter on a bridge]

Cut and split

Weathershed's cutter arrangements vary Individually, explained Lindstrom. "We have some cutters who only cut and split; some who cut, split, and hook; and some who even have their own trucks to haul it to the mill. All cutters provide their own chain saws and equipment. Although we do not require a minimum, many companies require a two-man team to produce at least two cords per day. If a unit has already been picked over once, the cedar is more scattered and this must be taken into account when discussing a cutter's rate."

Despite the fact that little if any falling is done and no heavy machinery is involved in cedar salvage, Weathershed Manager Paul Lewis reports cedar bolt operators are still assessed Oregon's staggering 32-percent workmen's compensation rate under the general logging classification.

"Except for an occasional cedar snag, no falling is done," Lewis relates. "And although some logs will shift after a certain amount is cut off, bucking is rarely hazardous since most of the cedar has been settled in position for nearly 30 years."

Workmen's compensation tacks on another 10-plus percent for the helicopter pilot for a walloping $42 payment per $100 salary.

Fastest fog in the West

With Georgia Pacific's closure rules distinguishing between yarder and aerial operations, Weathershed was not curtailed by fire restriction this year, but winds and rain would deter operations for up to three days at a time. Ground fog proved the most unpredictable.

"You could be flying along with clear visibility at 1 p.m. and by 1:05 ground fog could lower the ceiling to less than 100 feet," related Chief Pilot Mike Montgomery. "Frequently the work site itself may be clear, but you can't get there because of ground fog."

Army veteran Montgomery has flown over 1,000 of his 3,600 hours in Hillers. Weathershed also employs two Vietnamese pilots, Phuong Van Huynh and Tuan Ann Nguyen. Graduated from the Army Aviation School, Fort Wolters, [Mike Montgomery, helicopter pilot]

Tex., in 1970, Phuong and Tuan racked up over 5,000 hours each in combat from 1970 to 1975. Phuong escaped from Saigon two weeks before the Communist takeover and Tuan piloted a Huey to the safety of an American aircraft carrier the day Saigon fell. Both endured a year in refugee camps before finally securing a sponsor and settling In the Seattle area.

"We have found Phuong and Tuan to be hardworking, conscientous, and excellent pilots," said Loren Lindstrom. "For communications purposes we prefer to team each with a Caucasian, but we have encountered no serious problems in conducting our operations.

"Also, although we don't like to think of people in terms of cargo, most Vietnamese average about 100 pounds lighter than a Caucasian pilot, availing an additional 100 pounds for useful load. It's similar to putting a jockey on a racehorse," Lindstrom added.

Flying is a drag

In aerial cedar bolt operations, pilot fatigue is one of the biggest limiting factors in helicopter operations.

There is very little chance to relax," remarks Phuong Van Huynh. "You must constantly be stretching out to see the hookers. With a long line, it is eI ven more difficult to see the hookers even though they wear bright orange hats and vests. We usually fly for two hours, then rest two hours while the other pilot takes over. Then fly for another two hours."

"Sometimes, each pilot flies four hours straight, then is through for the day," added Montgomery, "I have flown up to 61/2 hours straight, but I was pretty well whipped."

Weathershed recently cancelled an order for a Hughes 500D to order their third Hiller Soloy Conversion.

"We are thoroughly satisfied with the performance of our Soloy Conversions," noted Loren Lindstrom. "We felt the slight difference in cargo capacity with the Hughes did not justify the extra $100,000 expense. Also, with only two blades to remove instead of five, the Hiller disassembles more easily for transportation to a new job site."

Gather your own

Pioneering aerial cedar bolt operations in Washington's Olympic Peninsula, James K. "Harold" Gunter, owner of Gunter Shake Mill and Peninsula Helicopters, operates two Hiller Soloy Conversions out of Forks, Wash.

Timber Talk

Like any industry (including helicopters), the timber business has developed its own vocabulary-and a colorful one it is. What

follows comes from Walter F. McCulloch's Woods Words published by the Oregon Historical Society (copyright 1958)

Accordion: A bucked log with a series of shallow shelves across the end, caused by poor bucking.

Against the log: A logging road grade where loads have to be hauled uphill.

Ax'er; To cut something loose in a hurry to avoid an accident.

Back 'er up: To cut the back side of a tree after the undercut has been put in.

Backfire: A very tricky job in fighting forest fires-setting fire in front of an onrushing main blaze.

Barber chair: A tree that is split up the trunk in falling, leaving the split portion on the stump instead of breaking through cleanly to the undercut.

Bearing tree: A tree marked to identify a survey corner.

Biltmore: A stick used by cruisers to estimate height and diameter of trees, developed by the Biltmore Forestry School,

Black gang: Loggers salvaging timber recently burned by forest fire.

Blind conk: Hidden decay in a tree.

Blow up: A fire that blazes up suddenly.

Bolt: A chunk of wood split or cut from a log generally for shakes or shingles.

Bucker: A man who cuts felled trees into log lengths.

Bug kill: Timber killed by insects.

Bull buck: Boss of fallers and buckers.

Bushel; To fall or buck by piecework rather than by daily wage.

Calks (or corks): Spiked woods shoes to give sure footing on logs.

Cedar fever: An itch sometimes affecting men working with red cedar.

Cedar savage: A logger working for a shingle bolt outfit.

Choker setter: The man who puts a steel cable or choker around logs to be yarded.

Clear cut: An area from which all timber has been removed.

Cold dock: To stack logs in a pile.

Cord: A measure of wood referring to a pile four by four by eight feet, or 128 cubic feet.

Cruiser (or timber cruiser): The man who estimates the quantity and quality of standing timber in a given area.

Deadfall: A trap of any kind; a dangerous situation. The expression comes from early-day bear traps that were built so that logs would be released by a trigger, fall on a bear and crush him to death.

Dehorn: To knock limbs off logs.

Devil dust: False smoke leading a watcher to believe a forest fire is starting.

Grade: Duality of a log.

Green cut: Logs cut from live timber.

Greening up (or haired up): A cutover area in which vegetation is starting to return after a heavy fire.

Gut a show: To take only the very best logs out of a stand of timber.

Gypo: To log by contract.

Haul: The distance over which logs are yarded.

Hazel hoe: A light hoe used for tree planting.

High lead: The widely used system of logging using a spar tree that carries the main line and haulback cables through blocks high above the ground. The high lead was a great advance over the low lead or ground lead method that it replaced, because in the latter

the logs were merely dragged on the ground and hung up on every rock and stump.

Hoot owl: To begin work early in the morning, as near daylight as possible, in order to get in a day's work before having to close down because of low humidity during the heat of the day.

Humpback: A logging truck returning to the woods with its trailer on its back.

Hung tree: A tree that becomes jammed against another as it starts to fall. Such trees are difficult and often dangerous to release.

Irish coupling: Logs not completely bucked through.

Jim Crow load: A one log load.

Kick back: The action of a falling tree in springing back off the stump as it comes down,

Landing: Flat ground where logs are yarded to be loaded onto trucks.

Leave strip: A strip of timber uncut between two clear cut areas.

Log brand: An ownership mark stamped into the end of a log to identify it when mixed with the other logs. Log brands are registered by law.

Looper: A small moth whose larval stage is a serious killer of coast timber.

Make bed: A leveling operation that will allow a tree to fall on at least three points all on one plane; made by bulldozing off humps and filling holes,

Needle scratching; Forester making seedling counts on cutover land.

Old growth: Virgin uncut timber.

Peeler: A log suitable for plywood,

Pulaski: A tool with an ax on one side and a light grub hoe on the other.

Scale: The number of board feet in a log.

Second growth: Young timber. In Douglas fir stands, applied to all stages of growth between saplings and red fir.

Single jack: To work alone as a faller.

Skidder system: A skyline method of logging -especially useful in rough country using a standing line, a big trolly, and a slack pulling system to lower the butt rigging to the crew.

Sleeper: A holdover fire.

Square: A measure of shingles or shakes; enough to cover 100 square f eat,

Stage cut: To fall timber in several rounds or successive cuts in order to reduce breakage.

Strip adjustment: A deal whereby a faller gets a little better rate for rough ground, scattered timber, etc.

Stumpage: The price paid for timber.

Sustained yield: A program of growing about as much timber in a given period as is cut curing that period.

Tally: In cruising timber, a measure of distance; five chains or 330 feet (99 m).

Undercut: The first cut made in a tree.

Whistle punk: The man or boy who passes signals from the choker setter to the donkey engineer when yarding logs. The starting job in a logging crew. A lot of fun is made of a green whistle punk, but if he makes a mistake in signals there will be fewer choker setters around.

Widow maker: A loose limb, top, or piece of bark that may fall on a logger working beneath it.

Yarder: An engine used to haul logs from stump to landing.

Olympic peninsula markets currently pay from $250 to $350 a cord, but Gunter reports higher Washington stumpages of $110 to $150 per cord working timber stands of ITT/Rainier and Crown Zellerbach. Washington cutters command rates of $85 to $115 a cord cut, slung, and hooked.

Peninsula Helicopters' General Manager John Ruhl has flown cedar for over a year since his discharge from the Army.

"We average 20 cords per hour with a 30-foot short line and 10 to 12 cords per hour for long line shows. Our fuel consumption is 26 gallons per hour," Ruhl said. "in terms of. cost per cord, we figure that with a 20- to 50-foot line it runs about $10 to $15 per cord, with a 50- to 100-foot line about $15 to $20 per cord, and with a 100- to 200-foot line about $20 to $45 per cord."

Forest fire restrictions curtailed Peninsula Helicopters' operations for two weeks this year. Wind is also a frequent problem.

"Unless we're running short line, we don't fly in winds over 20 knots, unless our own mill needs the wood," Ruhl admitted. "In addition to flying our own wood, we contract out for $250 an hour and you can't expect someone to pay that kind of money for less than top production.

"Just training a pilot inexperienced in long line logging operations frequently requires up to four months, during which his production is only half of expected capacity. One of the first things a customer will ask is, 'Is the pilot green? If so, they often demand hauling by the cord instead of by the hour.
"One advantage from a pilot's viewpoint though," Ruhl added, "is that pilots working cedar are rarely away from home, which compensates for the critical demands on a pilot's skill."

The cedar rustler ripoff

With cedar bolt sales tipping the scales at $250 to $350 per cord, weekend cedar thieves in the national forests are robbing the taxpayers of millions of dollars each year in Oregon alone. Although a felony with a maximum penalty of $10,000 or 10 years in jail, the afterwork woodcutter continues the lucrative practice, since detection is difficult despite an all out effort by the Forest Service, the FBI, and IRS.

Free use permits issued to local residents to cut cedar for fence posts and patio rounds further complicate enforcement.

In an effort to curb these timber thefts, the Oregon legislature passed House Bill 2891, which took effect Oct. 4,1977. It requires cedar buyers to maintain purchase records including the name, address, and signature of seller; date of sale; license number of transporting vehicle, quantity; and amount paid, Failure to maintain adequate records is a misdemeanor. As the bill only covers the wholesale transaction, it leaves a loophole for the middleman. Also, the current lack of record standardization creates a serious enforcement problem.

Neighboring Washington has passed a law effective Sept. 21, 1977, requiring everyone cutting cedar to have in their possession harvest and transportation permits signed by the proper landowner and endorsed by .the county sheriff. The new statute also requires cedar buyers to keep appropriate records of permit numbers and license numbers of delivery vehicles. (How's that for bureaucracy at its finest?)

To take some of the pressure off the enforcement problem, the Forest Service is now issuing scaling permits for five

cord lots and has Initiated aerial reconnaissance to catch thieves in the act.

Gunter emphasized the need for safety in his operation: "In the late1960s when helicopters were first used for hauling cedar on the Olympic Peninsula, 90 percent of the helicopter accidents In the Northwest were around here. The old recips couldn't stand the stress of continual cedar operations. Changing to turbine engines reduced vibration."

Gunter also finds pilot, fatigue one of the most critical safety factors: "We try not to schedule more than five hours a day flying time," Gunter explained, "with an average total of 80 hours per month. Although we've actually been running closer to 100 hours per month per ship."

"I can't stress maintenance enough," Gunter concluded. "Working in isolated areas, logistic support is often inade-quate so preventive maintenance is critical. With nine operators working the peninsula, this is a highly competitive market, but there's just no room in this business for short cuts!"

Bottom to the gold mine?

Without an established reforestation program, the future of cedar salvage is somewhat uncertain: Joe Hatfield of Pacific Cedar Logging estimated at least 15 to 20 years before cedar supplies dwindle beyond the commercially prof-itable level.

Weathershed is more optimistic about the future of cedar shakes. "Ten years ago, people were saying there were only about five years left in the business," said Loren Lindstrom. "With current mill technology, wood previously considered unsuitable can now be utilized and with the introduction of helicopters, cedar previously considered unprofitable because of its location is now readily accessible. I also expect a development of technology to utilize other species for shakes as well."

Although market projections vary from operator to operator, all agree the helicopter will continue to be an integral part of the shake industry.

Home

Helicopter animation by Jim Self