TFC CARBON TFC CARBON TFC CARBON

RIGGINGRIGGINGRIGGING

Navtec Fiber Rigging History

Through innovation and rigorous engineering Navtec has been at the forefront of yacht rigging for

over 30 years. As yacht design has evolved, Navtec has played an integral role in emerging

rigging technology. Beginning in 1986 with the introduction of Aramid rigging products, both soft

and pultruded, Navtec has been at the forefront of using high strength fibers as rigging.

In 1997, Navtec minimized rigging weight and maximized performance by taking advantage of the

extraordinary benefits of Zylon® fiber. Zylon®, better known as PBO, has allowed Navtec’s

engineers to create rigging that is 50% stronger and 80% lighter than comparable N-50 stainless

steel rigging assemblies. Navtec’s fiber solutions maximize performance through the use of

unidirectional cables. These cables were first introduced over 10 years ago using bi-conic

terminations.

Beginning in 2002, an extensive development program to produce continuously wound

unidirectional cables resulted in the Z-System PBO and Aramid product offerings from Navtec.

Over 1000 Z-System cables, on over 100 projects later, the Navtec design team continues to

improve the performance of this rigging system, making it the most trusted in the industry.

Recently, Navtec engineers have developed Thermo Fused Carbon (TFC) rigging which through a

patented termination method delivers the next level in high performance fiber rigging. TFC rigging

is the result of over 25 years of fiber rigging experience and testing. The patented termination

method unitizes precision tooling to create small terminations on a flexible carbon fiber cable.

GITANA XI with TFC lateral rigging

Navtec TFC can be used with existing rod rigging

deck, mast and spreader interfaces, making

conversion from rod rigging easy. Equipment

upgrades using titanium fittings can further optimize

the existing rigging package.

Navtec TFC is the latest innovation in carbon fiber

rigging. It is fabricated from an advanced carbon

fiber composite material. This flexible, high modulus

carbon composite material utilizes a thermoplastic

base that, when combined with an innovated

fabrication process, permits new options and

enhancements currently unavailable with other rigid

and flexible thermoset carbon fiber composite

rigging.

The TFC shroud is fabricated using a unique and

innovative patented process to form a method of

termination using 100% carbon fiber composite

material. The same high modulus thermoplastic

carbon fiber composite material that forms the

structural rigging midspan is molded and fused into a

configuration that physically interlocks into the

titanium end fittings. This high strength termination

requires no addition of epoxy or other adhesive

materials permitting the size of the fitting to be

minimized to decrease weight and the shape to be

optimized to reduce windage.

TFC weighs approximately one third the weight of

equivalent rod rigging. TFC offers a long life span as

well as improved durability when compared to

thermoset counterparts. TFC shrouds can be covered

with a variety of protective covers to prevent sail

damage and chafe at deck level or reduce friction for

a backstay application.

A Continuing Tradition of Excellence in Engineering and Innovation

TFC Carbon Rigging

TFC Rigging Lifespan and Service

Recommendations are based on the max working load not exceeding 40% of the cable breaking Recommendations are based on the max working load not exceeding 40% of the cable breaking Recommendations are based on the max working load not exceeding 40% of the cable breaking Recommendations are based on the max working load not exceeding 40% of the cable breaking

strength and the use of standard end fittings while adhering to Navtec Rigging guidelines.strength and the use of standard end fittings while adhering to Navtec Rigging guidelines.strength and the use of standard end fittings while adhering to Navtec Rigging guidelines.strength and the use of standard end fittings while adhering to Navtec Rigging guidelines.

Annual or every 10,000 milesAnnual or every 10,000 milesAnnual or every 10,000 milesAnnual or every 10,000 miles

• Complete inspection of the rigging and all installed rigging components by a Navtec authorized

rigger.

4 to 6 years or 40,000 to 60,000 miles4 to 6 years or 40,000 to 60,000 miles4 to 6 years or 40,000 to 60,000 miles4 to 6 years or 40,000 to 60,000 miles

• De-stepping of rig and complete inspection of the rigging including all installed rigging

components by a Navtec authorized rigger.

• Navtec supplied fittings and sockets

should be cleaned and all parts

nondestructive tested (NDT - this will

either be dye penetrative testing,

ultrasound or x-ray.)

• Hangers and turnbuckle screws would

at this time be replaced.

• N674 turnbuckle assemblies and

custom fittings need to be reviewed by

Navtec to determine remaining lifespan. A

recommendation will be made based on

usage, condition and mileage of parts

and rigging.

8 to 10 years or 80,000 to 100,000 miles8 to 10 years or 80,000 to 100,000 miles8 to 10 years or 80,000 to 100,000 miles8 to 10 years or 80,000 to 100,000 miles

• All 4-6 year check should be completed

• At this time the cable sockets and fitting

condition will need to be reviewed by

Navtec to determine remaining lifespan. A

recommendation will be made based on

usage, condition and mileage of parts

and rigging.

Swan 68 with TFC rigging

Frequently Asked Questions

How is TFC rigging built?How is TFC rigging built?How is TFC rigging built?How is TFC rigging built?

We start with a bundle of high end aerospace

grade carbon/ thermoplastic strands evenly

loaded. Then using a proprietary process

developed in house we fuse the strands over a

short distance at the ends into a solid bar.

Once a solid bar is created at each end of the

cable we use another proprietary and patented

process to form a head onto the end of the

solid bar. The head is formed using the existing

carbon thermoplastic material in the solid bar

reformed into a proprietary geometry.

What are the benefits of the TFC and the construction method?What are the benefits of the TFC and the construction method?What are the benefits of the TFC and the construction method?What are the benefits of the TFC and the construction method?

It allows for a flexible cable in the mid span that can be coiled into 3-5ft loop depending on sizes

and easily shipped around the world, avoiding difficult and complicated “on-site” curing or other

processing

Using the thermoplastic material we are able to consolidate the multi-strand mid span bundle

material down to a small diameter bar in the ends which allows the TFC product to have small

terminations reducing weight and windage.

The high end aerospace grade thermoplastic used as the matrix material to support the carbon is

a major advantage. The ability of material to be formed and then reformed opens up new options

to building composite rigging. The challenge is that it has to be processed at very high

temperatures (over twice other composites) using precision machined steel tooling. The tooling

and semi-automated process allows for tight quality control built right into the manufacturing

process.

What testing has Navtec done on the TFC rigging?What testing has Navtec done on the TFC rigging?What testing has Navtec done on the TFC rigging?What testing has Navtec done on the TFC rigging?

Using our 30 years of experience in the

rigging business Navtec has developed

design standards for the TFC rigging.

These standards are what we test the

rigging to using our in house testing

facility. The fittings are also designed to

the same standard. The testing includes

break, fatiuge, modulus and creep tests

along with other tests to confirm the

rigging meets and exceeds the Navtec

standard. The lab testing is then

backed up with ocean and buoy racing

with TFC rigged boats logging many

miles since introduction in 2011. FEA Analysis on TFC Lashing Eye

Material Comparison

Relative value of material compared to rod rigging

TFC Rigging

**Breaking Strengths and EA values can be customized on TFC rigging for special applications

TFC End Fittings

R532-06 Titanium Sockets

All Navtec TFC end fittings have been design to maximize weight reduction in the end termination.

The fittings are designed for any strength or stretch application in the TFC size. Our fittings use

standard pin sizes and dimensions that make retrofitting and new rigging application easy.

Alternatively, Navtec can supply any number of custom fittings to suit specific applications. The

small female thread in our TFC terminal offers one of the most versatile attachment methods

available. Virtually any custom fitting design can be adapted to fit our TFC cables.

Swan 90 with TFC rigging

Ø B L

ØOD

THREAD

R532-07 Titanium Marine Eyes and Socket Assembly

R532-08 Stainless Steel Barrel Pin Eyes and Socket Assembly

Ø HOLE

B A

W

T

C

Ø PIN

B A

W

T

C

R532-20 Titanium Lashing Eyes and Socket Assembly

R532-30 TFC Stemball Studs and Socket Assembly

L2

R

A

W

L1

B

T

L2

L1

R532-30 Long Stemball Studs and Socket Assembly

R532-31 Micro Stemball Studs and Socket Assembly

L2 L1

L2 L1

R532-31 Long Micro Stemball Studs and Socket Assembly

R532-34 Titanium Tip Turnbuckles and Socket Assembly

L2 L1

LENGTH

R532-51 Threaded Stud and Socket Assembly

N674 Turnbuckle with R532-51 Threaded Stud and Socket Assembly

L2

L1

THREAD

Ø PIN LENGTH

C B

A

D

C790-BP Telescoping Barrel Pin Turnbuckle and Socket Assembly

C790-TG Telescoping Toggle Turnbuckles and Socket Assembly

LENGTH B A

W

T

Ø PIN

Ø PIN LENGTH

A

C

B

Navtec Barrel Pin Chainplate Dimensions

Pin Material Should Meet 190 KSI Min. UTS (1310 Mpa)

PBO Retro Fit Case Study

To allow cost effective refit of older PBO rigging Navtec has

developed a spreader termination which allows easy

replacement of PBO with TFC rigging.

• Reuse existing spreaders without the need

to make modifications saving cost and time

• TFC rigging has a significantly longer

lifespan when compared to the PBO

• Similar weight and windage compared to

PBO rigging