FORCON INTERNATIONAL VIRGINIA, LTD.

Gaskins Centre 1 / 3827 Gaskins Road / Richmond, Virginia 23233-1436

804/230-4820 804/230-4857 FAX www.forcon.com
Providing Forensic Consulting and Technical Services since 1984
October 6, 2014
Mr. Darrell Scott
Inflatable Jump Rentals
9529 Whitehall Blvd.
Spotsylvania, Virginia 22553
Subject: Eliminator Jump Design Review
FORCON CASE #V14636
On September 30, 2014, you requested FORCON to perform a design review of the
Eliminator Jump amusement device.
On October 2, 2014, Michael Pinion of FORCON inspected the electrical assembly of
the Eliminator Jump.
On October 3, 2014, James Laird of FORCON inspected the broken sweep pole,
replacement pole and the repair offered by SQ Amusement Supply Company. James
Laird also reviewed applicable ASTM standards.
FORCON observed and noted the following:
Mr. Scott reported that the Eliminator Jump was purchased from SQ
Amusement Supply Company in November, 2013 and received in
January, 2014. The original sweep pole provided with the unit bent
downwards during the first rental when in use by children and had to be
adjusted multiple times to continue operating. The pole fractured during
the second rental of the unit. SQ Amusement Supply Company provided a
replacement pole and replacement pole mount to fix the issue. The
replacement pole mount failed in about 40 minutes of use without anyone
using the device. The replacement pole and original pole holder were
used for one more rental without fracturing and the amusement device has
not been used since. The device did not come with directions or a user
manual and the manufacturer was not known. The device did not have a
known age restriction or weight limit.
The overall length of the pole was about 10 feet with the last 3 feet
consisting of a solid plastic rod. The foam covering added another 7.5
Eliminator Jump Inspection
FORCON No. V14636
October 6, 2014
Page 2
inches to the length of the pole. The pole had fractured and separated 12
inches from the end of the pole that had been inserted into the pole
holder. (Photographs 2-3)
The metal pole had an outer diameter of about 1.8 inches and a wall
thickness of 0.048 inches. The pole had kinked and fractured.
(Photographs 4-6)
The solid plastic pole was about 1.5 inches in diameter and was
connected to the metal pole with tape and 3 screws. (Photographs 7-8)
The replacement pole holder provided had been cut and modified by SQ
Amusement Supply Company to use a hinge and shock to allow the pole
to deflect downwards when fallen on instead of bending the pole. The
welds on the pole holder had poor penetration and consistency. The welds
did not meet the requirements of ANSI D1.1 Structural Welding Code.
(Photographs 9-13)
The pole with padding weighted about 27 pounds. (Photograph 14)
A bonding jumper was not installed between the grounded box and the
hinged door containing electrical controls. The equipment was not
provided with a Ground-Fault Circuit Interrupter (GFCI) nor was it labeled
requiring the product to be used with a Ground Fault Circuit Interrupting
(GFCI) outlet. (Photograph 15)
Holes through the metal framing for cable transitions were cut by a torch
leaving projections, sharp edges, burrs of metal protruding into the cable
way. Cable transitions through metal members should have a smooth,
rounded surface against which the cord may bear and shall be free from
projections, sharp edges, burrs, fins, and the like that may cause abrasion
of the insulation on the conductors. The appliance power cord was not
installed with a bushing as it passed through holes in the metal framing.
(Photograph 16)
Improper electrical connections were made using solder with excessive
flux to terminations. (Photograph 17)
The appliance power cord was not installed with a strain relief as it
entered the control box. A strain relief should be provided so that
mechanical stress on a flexible cord will not be transmitted to terminals,
splices, or interior wiring. (Photograph 18)
The pole was not able to withstand the impacts involved with the normal use of the
device. The plastic rod was too stiff to dissipate the impact forces and forces from the
users falling onto the pole. No device weight or age requirements were provided with
the Eliminator Jump. Amusement Rides and Devices indicates that 170 pounds should
be assumed for an adult when designing an amusement device. Engineering
calculations using the yield strength for a low grade steel show that the pole will fail with
a static load of about 25 pounds when applied at a distance of about 8 feet from the
Eliminator Jump Inspection
FORCON No. V14636
October 6, 2014
Page 3
pole holder, not including dynamic loading from the impact of a user falling onto the
pole. ASTM F1159 Standard Practice for Design and Manufacture of The pole
strength was insufficient for the normal operation of the ride. ASTM F1193 Standard
Practice for Quality, Manufacture, and Construction of Amusement Rides and Devices
requires welding to meet ANSI requirements and Operation Instructions to be provided
with each device. The replacement pole holder provided by SQ Amusement Supply
Company was poorly welded and did not meet ANSI welding requirements.
FORCON concludes that the design of the Eliminator Jump, a thin walled pole and stiff
plastic rod, caused the pole to bend and break under normal operation. The
replacement pole holder failed owing to welds with poor penetration. The electrical
assembly of the Eliminator Jump did not conform to electrical industry safety practices.
The design of this Eliminator Jump was not suitable for the intended purpose of the
device.
Please call if you have any questions. Our invoice is enclosed for this work.
We appreciate the opportunity to assist you.
, s d r a g e r h t i W


James W. Laird, BSME, CFEI, CVFI Michael G. Pinion, PE, CFEI
Mechanical Engineer Electrical Engineer
Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 4




PHOTOGRAPH # 1 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The Eliminator J ump components as received by FORCON.

COMMENTS:


Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 5



PHOTOGRAPH # 2 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: Measuring the failed pole sweep.

COMMENTS: The left arrow points to the location of the failure. The right arrow points to
the joint between the plastic and metal tubing.



Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 6



PHOTOGRAPH # 3 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The pole end next to the pole mount.

COMMENTS:



Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 7



PHOTOGRAPH # 4 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The outer diameter of the pole was about 1.8 inches.

COMMENTS:

Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 8



PHOTOGRAPH # 5 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The wall thickness was about 0.048 inches.

COMMENTS:
Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 9



PHOTOGRAPH # 6 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The kink and fracture.

COMMENTS:

Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 10



PHOTOGRAPH # 7 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The transition from the metal tubing to the plastic rod.

COMMENTS: The plastic rod was wrapped in tape and inserted into the tubing, held in
place by 3 screws.
Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 11



PHOTOGRAPH # 8 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The diameter of the plastic rod was about 1.548 inches.

COMMENTS:













Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 12



PHOTOGRAPH # 9 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The replacement pole holder.

COMMENTS:


Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 13



PHOTOGRAPH # 10 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The failed weld at the hinge.

COMMENTS: The arrows point to the surfaces that had been welded together.



Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 14



PHOTOGRAPH # 11 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The weld on the hinge.

COMMENTS: The weld had poor penetration and consistency.









Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 15



PHOTOGRAPH # 12 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The weld on the top tube.

COMMENTS: The arrow points to one of the few locations where any penetration
occurred. Most of the weld had no penetration.







Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 16



PHOTOGRAPH # 13 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: Shock mount weld.

COMMENTS: Most of the welds on the pole mount had poor penetration and
consistency.


Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 17





PHOTOGRAPH # 14 DATE TAKEN: 10-3-14 FORCON #V14636

SUBJ ECT: The weight of the pole was about 27 pounds.

COMMENTS:



Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 18




PHOTOGRAPH # 15 DATE TAKEN: 10-2-14 FORCON #V14636

SUBJ ECT: Control Cabinet.

COMMENTS: Control Cabinet without bonded jumper between grounded box and door.
The appliance power cord was not installed with a strain relief.
The equipment was not provided with a Ground-Fault Circuit Interrupter
(GFCI) nor was it labeled requiring the product to be used with a Ground
Fault Circuit Interrupting (GFCI) outlet.


Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 19



PHOTOGRAPH # 16 DATE TAKEN: 10-2-14 FORCON #V14636

SUBJ ECT: Control Cabinet Base.

COMMENTS: Holes through the metal framing were cut by a torch leaving projections,
sharp edges, burrs of metal protruding into the cable way.
The appliance power cord was not installed with a bushing as it passed
through holes in the metal framing.



Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 20



PHOTOGRAPH # 17 DATE TAKEN: 10-2-14 FORCON #V14636

SUBJ ECT: Improper electrical connection using solder with excessive flux to
terminations.

COMMENTS:

Eliminator J ump Inspection
FORCON No. V14636
October 6, 2014
Page 21



PHOTOGRAPH # 18 DATE TAKEN: 10-2-14 FORCON #V14636

SUBJ ECT: Improper strain relief at motor connector plug.

COMMENTS: