Composite Strapping

Material and Construction

Composite strapping is manufactured from high-tenacity polyester filaments combined with a polymer (polypropylene or polyethylene) coating or matrix. Two primary construction types are available: cord strapping, where parallel polyester yarns are bonded within a polymer coating, and woven strapping, where polyester filaments are woven in a cross-pattern for multi-directional strength. Both constructions produce a strap that combines high tensile strength with flexibility, shock absorption, and safe handling characteristics.

Composite vs. Steel Strapping

Composite strapping is engineered as a direct replacement for steel strapping in applications where safety, weight reduction, and corrosion resistance are priorities. Key differences from steel strapping include:

• Weight: Composite strapping weighs approximately 75% less than equivalent steel strap, reducing shipping costs and making handling easier for operators.
• Safety: Composite strapping does not produce sharp edges when cut or when it fails under load. Steel strap under tension can snap violently and cause serious lacerations.
• Corrosion: Composite strapping does not rust, corrode, or stain products. It maintains full strength through exposure to rain, humidity, and chemical environments.
• Shock absorption: The 3-5% elongation of composite strapping allows it to absorb transit shocks and vibrations without losing load integrity, while rigid steel strap can crack or loosen under repeated impact.

Cord vs. Woven Construction

• Cord strapping consists of parallel polyester yarns bonded within a smooth polymer coating. It provides high linear tensile strength and is commonly used with wire buckles. Available in widths from 1/2 to 1-1/4 inch with break strengths from approximately 1,070 to 3,300 lbs.
• Woven strapping uses a cross-woven pattern of polyester filaments that provides multi-directional strength and higher resistance to edge cutting and abrasion. Available in widths from 3/8 to 1-1/2 inch with break strengths from approximately 600 to 6,125 lbs. Woven strapping is preferred for loads with sharp edges or rough surfaces that could damage cord-style strapping.

Width and Break Strength Selection

• 1/2 inch (13 mm) provides break strengths from approximately 1,070 to 1,200 lbs for light to medium-heavy loads.
• 5/8 inch (16 mm) provides break strengths from approximately 1,320 to 1,800 lbs for general industrial load securing.
• 3/4 inch (19 mm) provides break strengths from approximately 1,600 to 2,700 lbs for heavy-duty pallets and shipping containers.
• 1 inch (25 mm) provides break strengths from approximately 1,730 to 3,500 lbs for heavy machinery, lumber, and steel replacement.
• 1-1/4 to 1-1/2 inch (32-38 mm) provides break strengths from approximately 3,300 to 6,125 lbs for the heaviest industrial loads, rail freight, and maximum-strength applications.

Sealing and Tensioning

Composite strapping is secured using wire buckles, metal seals, or crimp-style clips rather than the friction-weld or heat-seal methods used with PP and PET strapping. Tensioning is performed with manual windlass tools, ratchet tensioners, or pneumatic tensioners. The buckle-based sealing system does not require battery-powered or pneumatic sealing tools, making composite strapping practical for field applications where power tool access is limited.