Tow Engineer

Synthetic ropes are available in a variety of shapes, sizes and different types of construction.

The Skinny on Synthetic Rope & Chain

By Terry Abejuela

Field Editor Terry Abejuela has 40-plus years of light-duty towing and recovery experience. He is also a light-duty Level 1 instructor for the California Tow Truck Association. Steel rope and chain have been a staple of the towing and recovery industry since the beginning but like most industries the tools and equipment we utilize are constantly evolving to meet our changing needs. Synthetics may not replace steel anytime in the near future but they do provide us with another tool to perform the job more effectively, efficiently and safely.

There are many different types of synthetic fibers available so take a look at the characteristics of the fiber used in the synthetic winch rope or synthetic chain before deciding which to purchase. Different fibers may have different strengths, UV resistance, abrasion resistance, heat resistance, chemical resistance and weight. Dyneema seems to be the fiber of choice for synthetic winch line ropes and synthetic chain.

SYNTHETIC ROPE

Synthetic ropes have many benefits including lightweight, strong, low stretch, no memory, floats on water, nonconductive, won’t cause sparks, it is quiet, less potential for damage, is safer on hands and low recoil. If you conduct frequent water recoveries, a rope that floats is definitely a great benefit. Of course the hook on the end of the rope will sink in water. No memory means that the rope does not kink and can wind back on its’ self and not create permanent flat spots. The best benefit is that it is safer to use.

Should the synthetic rope fail under load there is much less energy released when compared to steel rope. Because the rope is lightweight and soft there is less potential for injuries. There is a steel hook on the end of the rope so make sure to use a positive attachment winch line hook

and secure attachment point to avoid the potential for the hook to dislodge and cause injury or damage. Handling of the rope is easier because there are no broken wires that can cut through gloves and cause hand injuries and it is much easier to pull off the drum in free spool.

Synthetic ropes are available in a variety of shapes, sizes and different types of construction. Just like steel ropes, synthetic ropes are often constructed to perform a specific task. Not all ropes will be intended for use as a winch rope. Make sure to choose a rope that is constructed and intended to do the job you want. There are ropes that are laid or braided, left or right hand lay, covered and even specially treated like plasma ropes.

Before making the decision to replace the wire rope on your winch consult the winch manufacturer for their input. Winches, sheaves, snatch blocks and fairleads will need to be inspected ◀

The rope should still be wrapped tight and evenly but if it is not it will not cause permanent damage.

and cleaned to remove any rough areas or sharp edges. The winch manufacturer should provide an approved method to attach the rope to the drum. Consult the synthetic rope manufacturer for the recommended installation guidelines. Some rope manufacturers recommend light tension when wrapping the first five wraps on the drum and then power wrapping the rest of the rope under loads close to or equal to the working load limit of the rope.

When winching loads with a synthetic rope on the winch drum I recommend that you maintain a minimum of 10 wraps around the winch drum.

Use protective sleeves to prevent abrasion damage and cuts to the fibers in the rope.

Make sure the synthetic rope is sitting properly in any sheaves it runs through. If the rope runs over the edge of a sheave under a load it can be severed.

Inspection and maintenance of synthetic rope is much different than that of steel rope. Synthetic rope does not require lubrication. The rope should still be wrapped tight and evenly but if it is not it will not cause permanent damage. Flat spots will disappear when the rope is under a load. The rope can be massaged by hand to bring the rope back to it’s normal shape.

Dirt, sand, mud, small pebbles, and salt from use in salt water recoveries can cause abrasion damage to the rope. Keep the rope clean by washing it in a bucket of soapy water. Wash it a section at a time and leave the cleaned portion of the rope out of the bucket of dirty water to avoid dirt

Synthetic ropes have many benefits.

and debris being reinserted into the rope. Allow the rope to air dry before reinstalling it on your winch drum.

Inspect the synthetic rope frequently looking for abrasion damage, cut strands, heat damage, chemical damage, or inconsistent diameter. Synthetic rope that has been used will show some normal wear and tear that does not reduce the working load limit. Many synthetic rope manufacturers have literature available with pictures showing the difference between acceptable wear and tear and damage that must be repaired or the rope replaced. I recommend using the resources available from the rope manufacturer to help you maintain the integrity of the rope. Some damages can be repaired such as compression damage or a pulled strand. Compression damage can often be repaired by flexing or massaging the rope back to normal shape. A pulled strand can often be worked back into the rope by hand. Some damages, if affecting only a small portion of the rope, may be cut out of the rope and the rope respliced.

SYNTHETIC CHAIN

The latest synthetic fiber development to be introduced to the towing and recovery industry is synthetic chain. Synthetic chain links are made of 100 percent Dyneema fiber with 8 layers of webbing in a Mobius twist with stitching on each side. Synthetic chain has all the same benefits as synthetic rope. The most important benefits are the safety benefits of less recoil and potential for injury in the event of failure.

It is intended to be used in lashing applications and is currently not intended for overhead lifting. I believe it is in the works to be approved for overhead lifting but may not be approved yet. I think one of the reasons it was not intended for overhead lifting is the design factor that was used. In a lashing application it has a ◀

Synthetic chain not approved for overhead lifting. design factor of 2 to 1. A breaking strength of 20,000 pounds has a working load limit of 10,000 pounds. In the towing and recovery industry it is common to use a minimum of a 4 to 1 design factor, so a 20,000 pound breaking strength would be a 5,000 working load limit.

Just like steel chain, twisting of the chain will affect the chains performance. A maximum of 0.5 turns per 3.28 feet is allowed. A clear open link in every third link indicates the chain has no twist.

Synthetic chain has all the same safety benefits of synthetic rope.

Synthetic chain is designed to be maintenance free but must be kept clean to avoid damage to the fibers.

According to the manufacturer the chain can be washed in an industrial washing machine. Some feel that cleaning in a washing machine may cause premature wear on the links so you could hand wash the chain in a bucket of soapy water.

Synthetic chains should be frequently inspected for wear, tears, cuts, abrasion damage, damaged stitching, chemical or heat damage. There should be no spreading of the layers.

Synthetic fiber technology is constantly improving and in the near future there may be fibers available that are more resistant to heat, chemicals, abrasion and cutting making them even more beneficial for the towing and recovery industry. Even though synthetic fiber ropes and chains are more expensive than their steel counterparts, I think the safety benefits outweigh the cost.