The 2024-2025 Vendée Globe has once again demonstrated the extreme demands placed on both sailors and their equipment. This edition not only highlighted human endurance but also served as a crucible for testing and refining sailing deck hardware. With continual advancements in yacht design, sail technology, and foil development, loads on deck hardware are increasing significantly, requiring more robust and technically refined solutions. Drawing insights from the race, particularly through the lens of Karver Systems' involvement, we can discern key lessons and trends shaping the future of deck hardware development.
Increased Loads and Material Demands
New IMOCA yachts are now equipped with load sensors, providing a more precise picture of real-world forces acting on deck hardware. Data from these sensors confirms that peak loads now rarely exceed the working load of high-performance products. However, had older-generation boats been equipped with the same sensors, they would likely have recorded only 50% to 75% of today’s loads. This suggests that over the past decade, average working loads have increased by 25-50%, placing significantly greater strain on components such as jammers, furlers, winches, and deck blocks.
For example, modern furling units must withstand tack loads exceeding 10 tonnes, compared to 6-7 tonnes on older designs. Similarly, backstay and mainsheet jammers, which in previous editions of the race might have seen maximum loads of 5-6 tonnes, are now frequently experiencing 7-9 tonnes in dynamic conditions, requiring improvements in material selection, load distribution, and engagement mechanisms.
Average Speeds and the Influence on Deck Hardware
Alongside increased loads, the overall performance of IMOCA yachts has dramatically improved. Average speeds have risen by 20-25% compared to a decade ago, with sustained speeds of 25 knots now becoming more common. This increase, driven largely by second-generation foils, means that hardware is subjected to significantly greater dynamic loads and impact forces. The interaction between these foils and the rig creates additional demands on equipment such as stays, furlers, and line handling systems, which must now endure sudden load variations and extreme stress cycling.
For instance, furling systems must not only manage increased load but also operate reliably under significantly higher acceleration forces as yachts crash off waves at 30+ knots. The evolution of hardware must therefore prioritise both strength and resilience while maintaining minimal friction for efficient handling.
Evolution of Rope Management and Jammers
As a result of increased loads, rope handling systems have had to evolve. High-load jammers, particularly those used for running backstays, foil controls, and tack lines, are now expected to hold up to 10 tonnes while still allowing smooth release under extreme tension. This is a critical requirement for both safety and performance, as these lines often need to be eased dynamically at high speeds.
The development of locking headboard cars is another area of innovation. Previously, these systems primarily functioned to prevent mainsail creep when reefing. Now, they must handle significantly higher halyard loads, as well as repeated cycles of engagement and disengagement under load, particularly in sea states that cause erratic shock loading on the rig.
The Role of Real-World Testing
While laboratory simulations and controlled testing environments provide valuable insights, real-world performance remains the ultimate benchmark. The Vendée Globe serves as an uncompromising test bed, where products are subjected to relentless use over three months of continuous sailing. Failures at sea drive manufacturers to refine their designs, whether by optimising load distribution, improving engagement mechanisms, or advancing material science.
For example, Karver Systems’ external furling locks, used by multiple teams, provided a crucial advantage in sail management. These locks not only reduce halyard loads but also enable more efficient furling under tension—an increasing necessity given the added forces at play. However, feedback from this edition of the race suggests further refinements are needed in high-shock environments, particularly where repeated furling and unfurling cycles expose hardware to fatigue.
What’s Next? The Future of High-Performance Deck Hardware
Looking ahead, the lessons from the 2024-2025 Vendée Globe indicate several key trajectories for deck hardware development:
- Advanced Materials: Composites and hybrid metal alloys will continue to replace traditional stainless steel components, reducing weight while maintaining or exceeding existing strength thresholds.
- Dynamic Load Absorption: With peak loads increasing, manufacturers must develop hardware that can better manage transient force spikes, whether through elastomer-based shock absorption or refined engagement geometries.
- More Efficient Line Handling: Reduced friction and improved load management will remain priorities, particularly as line diameters decrease to compensate for higher loads without excessive weight penalties.
- Integrated Sensor Technology: Load monitoring hardware will become more commonplace, allowing sailors to make informed decisions on deck equipment limits in real-time.
The Vendée Globe remains the ultimate proving ground for sailing hardware, driving continual innovation in pursuit of reliability, efficiency, and performance. The ever-evolving demands of ocean racing will ensure that deck hardware manufacturers remain at the forefront of material and design advancements, shaping the future of high-performance sailing.
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Lessons from the 2024-2025 Vendée Globe: Evolving Demands on Sailing Deck Hardware