Guide to the perfect rigging for your boat: expert advice

In the world of high-performance sailing, every detail can make the difference between a win and a loss. The materials, sizing, and consistency of the entire system are key elements in ensuring high performance and reliability in racing. And in the world of cruising, where safety is at least as important as comfort, the music does not change.

The evolution of rigging:
what the latest
editions of the America’s Cup and Vendée Globe teach us

In a two-way dialogue, Luigi Maffioli, Technical Director of Gottifredi Maffioli (and one of the most beloved faces in our Vendée Globe Process), a historic Italian brand considered an international excellence in the world of ropes and rigging, and Raffaele Fredella, member of Luna Rossa Prada Pirelli ‘s shore team and rigger in charge of the mast in the 37th America’s Cup; share their experiences and help us understand how the evolution of materials has transformed the way rigging is designed and used on the world’s most competitive boats. And how you “lead” and influence the cruising world as well.

Rigging, why is consistency in sizing so important in a sailboat?

In designing a sailboat, every detail can make a difference, as Luigi Maffioli explains, “The role of the rope manufacturer must be considered within the boat design process. The textile must adapt to the loads of the other components to ensure the best possible balance.”

From Raffaele Fredella’s experience, the development of specific elements, such as a loop used as a fuse with a calibrated breaking load, can be decisive in avoiding compromising the entire system. This approach makes it possible to handle potentially catastrophic situations, demonstrating the importance of careful and targeted design. Attention to detail must apply to the whole boat, not just the lines.

Very often, in fact, there is a lack of consistency in sizing; for example, in a cruising boat, with Dacron sails and a fiberglass hull, the halyards and sheets need some elasticity. Conversely, in boats with carbon mast and sails, it becomes essential to opt for stiffer materials, such as Dyneema.

Dyneema SK78 or Dyneema SK99: how to choose the right material?

One of the most common mistakes when choosing materials is the belief, that the stiffer one is always the better choice. For example, between Dyneema SK78 and Dyneema SK99 there is a 30% difference in stiffness; with the same diameter, this choice can radically change workloads. In addition, Dyneema SK78 can be appreciated for its reliability in particular more stressful cases, for example, at large deflection angles.

Although switching from polyester to Dyneema is an obvious category jump, the difference between Dyneema SK78 and SK99 should not be underestimated. The problem arises when the selection is made without considering the implications. It is not enough to choose the material with the highest breaking strength; it is necessary to think about how it will integrate with the rest of the system.

How has the process of summit development evolved over time?

In the past, rigging design was much more empirical, based on field trials and feel. The stocking of the line was modified to get more or less grip, but it all depended on the crew’s experience. Today, however, it has become much more engineered.

There is a need to be certain that the modulus, strength, and efficiency values of materials are reliable and repeatable. This need stems from the fact that modern boats are much more sophisticated. In the past, line handling was mainly through winches, with crew sensitivity making the difference; with the advent of AC75 and foil technology, almost everything is now moved by hydraulic actuators and automated systems.

“We no longer have sheets in our hands, no more winches to turn. Everything goes through hydraulic cylinders connected to the textile, and here precision becomes mandatory,” explains Raffaele Fredella. This new approach has also led to a change in product development philosophy, as Luigi Maffioli explains, “We no longer aim only for high performance, but also to ensure its reproducibility and reliability under extreme conditions.”

How have the demands of sailors changed in their choice of ropes?

In recent years, a big difference from the past has emerged in the level of product customization. Whereas in the past people worked with standard sections, they now find themselves developing intermediate measurements, even at half-millimeter levels. This increasing focus on precision is directly fueled by the teams, who require even quarter-millimeter variations.

Attention to detail is also reflected in the design of the strop socks. During the last campaign, a range of specific covers was developed for certain strops, refining the weaving to achieve perfect grip, durability and smoothness. The importance of dialogue between those who produce and those who use is crucial, says Luigi Maffioli. “It used to be that we would test a product in the field and modify it if necessary. Today we can predict material behavior with great accuracy as early as the design stage, reducing the need for field testing and improving reliability .”

“This precision is not an end in itself. It is what allows us to take technology further and further and push the limits of performance in America’s Cup and ocean racing.” adds Raphael Fredella.

How do you balance reliability, safety, and innovation in modern rigging?

Over the past decade, knowledge of materials has advanced enormously, making it possible to predict how they will behave in real-world conditions. This progress is particularly crucial in critical applications, such as Dyneema stays, whose length can vary with temperature and time of use. This challenge has required the creation of real mathematical models, the result of extensive analysis and experience.

Precisely because of this, it has been possible to reduce safety coefficients without compromising reliability. In industry, the safety coefficient for textiles is around 7, while for cruising boats it is about 4. In the world of racing, it goes down to 3, and in the America’s Cup it is even as low as 2.

This improvement allows the use of lighter, higher-performance materials, but it also requires constant monitoring. Fredella continues, “In the America’s Cup, every day the team takes the boat apart, meticulously checking every single loop, strop and connection, even analyzing wear and tear from the inside-a level of care that only a professional team can afford.”

For ocean sailors, on the other hand, as in the case of the Vendée Globe, every aspect of design must take into account the need to withstand months of use without the possibility of maintenance.

From the racing world to everyday sailing: what can we learn?

The link between the world of racing and everyday sailing offers valuable insights for ordinary sailors as well. In addition to the physical training of sailors, awareness in the choice of rigging can lead to significant improvements.

Accurate sizing is essential to ensure both the durability of the rigging and its proper functioning with the rest of the deck equipment. A finer line may help creep but be undersized relative to breaking loads, while a thicker-than-necessary maneuver may increase friction in different passes, thus accelerating wear rather than reducing it.

Equally crucial is the choice of materials: although a Dyneema SK99 may appear to be the best solution due to higher workloads, it is not always the right choice for every application. The increased stiffness can put undue stress on improperly sized stoppers, thus leading to slippage under load. One must therefore, once again, consider the whole chain, including perhaps putting ceramic stopper cams on when switching from a DSK 78 halyard to a DSK99 halyard.

One advantage of Dymeema SK99 we find in “retrofit” work, allowing us to keep sections small even when we need to replace lines in typical steel cable applications.

This attention to detail, taken to the extreme in the context of the America’s Cup, can also make a difference on a dinghy or cruising boat. Understanding how to properly select and use lines is critical to improving performance and ensuring safety while sailing.

An ongoing dialogue between innovation and use

The evolution of rigging is an ongoing process. Each competition brings new challenges, new knowledge, and new solutions that, over time, become available even for more traditional sailing.

Dialogue between manufacturers and users is critical to developing increasingly high-performing and reliable products. In-depth knowledge of materials and the ability to apply them in the right way make the difference between rigging based on empirical observations and an optimized system.

Whether it is an America’s Cup boat or a cruising boat, the principle remains the same: choose the right material, in the right size, for the right use. Because at sea, accuracy is everything.

Lamberto Cesari – Gottifredi Maffioli