Cable-based technologies have been a backbone for harvesting on steep slopes. The layout of a single cable road is challenging because one must identify intermediate support locations and heights that guarantee structural safety and operational efficiency while minimizing set-up and dismantling costs. Our study objectives were to (1) develop an optimization approach for designing the best possible intermediate support layout for a given ground profile, (2) compare optimization procedures between linearized and nonlinear analyses of a cable structure and (3) investigate the effect of simplifying a multi-span representation. Our results demonstrate that the computational effort is 30–60 times greater for an optimization approach based on nonlinear cable mechanical assumptions than when considering linear assumptions. Those nonlinear assumptions also stipulate lower heights for intermediate supports and a larger span length. Finally, compared with the unloaded case, tensile force in the skyline is increased by as much as 80% under load for a single-span skyline configuration. Our approach provides additional value for cable operations because it ensures greater structural safety at a lower cost for installation. Improvements are still needed in developing a stand-alone application that can be easily distributed. Moreover, our rather simple assumptions regarding set-up and dismantling costs must be refined.
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