One of the top questions we get at Warn is which is better: steel rope or synthetic rope? Well, the answer depends on a few factors. In this video, we'll take a closer look at the question about whether steel or synthetic is right for you.

Video Transcript

My name is Andy Lilienthal; I work in the marketing department at Warn Industries, and I've been into off-road for about 13–14 years. Today we're going to talk about the difference between steel versus synthetic line. This is one of the topics and one of the questions that we get asked most often both online and at shows, so we're going to talk a little bit about the differences, why you would choose one over the other, and the advantages and disadvantages.

Steel Rope

Steel rope is the original winch rope and until recently it's the only choice that you've ever had. In fact, we've been using steel ropes since 1959 when we pioneered the electric winch.

Steel rope is extremely durable and abrasion resistant, which is why it's the top choice still for industrial applications such as the towing world, or if you're using it to skid logs around a property. Our wire rope is made from aircraft-grade galvanized steel and it is spec'd by our engineers with the appropriate weave, diameter, and length to work in conjunction with WARN winches. The capacity will far exceed the winch's rated capacity as well.

Our wire rope comes with a hydraulically swaged end with an eyelet that you'll attach your hook or shackle mount to. On the other end you have an eyelet that bolts to the side of the winch drum — that's how it attaches to the winch itself. When used properly, the wire rope is designed to exceed the stall point on the WARN winch.

The top benefits for steel rope are its exceptional abrasion resistance — you can run this over rocks, stumps, or anything else and it's not going to compromise the line at all. This is one reason why it's oftentimes still used in industrial applications such as towing. Steel rope is also UV resistant and fairly chemical resistant; frankly this stuff can basically last forever. You'll want to do regular inspections for kinks, but it's extremely durable.

There are cost benefits associated with wire rope as well. It's about a quarter of the cost over the lifespan compared to synthetic rope, so the overall price of a winch with steel rope — or even steel rope on its own — is going to be less than synthetic.

Steel rope does have some disadvantages compared to synthetic. One is that it's heavier, and to some people weight is a factor. Over time it can develop barbs in the line — that's why you always want to wear gloves when handling wire rope. In addition, handling in general can be a little more cumbersome than synthetic. It can bird's nest, it can be less flexible and a little more difficult to work with. When under load, steel rope can hold an incredible amount of energy, so when you're winching and bring it under tension it will have quite a bit of energy tied up in it. You definitely need to treat it with respect, follow best practices, and follow all safety procedures including using a damper on the line. It's a great tool — but you have to treat it accordingly.

Synthetic Rope

So now we're going to take a look at synthetic. Synthetic rope originally originated in the marine industry and has become popular with vehicle recovery winches in the last 15 years or so. This happens to be the WARN Spydura Nightline, but we offer a couple of different variants.

WARN Spydura is made out of ultra high molecular weight polyethylene (UHMWPE) and it is super strong. The rope is coated in a special urethane that helps protect it against UV and also helps keep some of the dirt and grit out of the weave. Spydura comes with an abrasion sleeve — if you're winching over something abrasive or sharp, such as a rock or stump, you would position this on top of that item so the rope passes through the sleeve, saving the rope and providing a longer service life.

Synthetic rope is exceptionally strong, but also very lightweight. We make Spydura for truck winches 16,500 lbs. and under, so it's compatible with pretty much all of our truck winches. One of the most popular benefits of synthetic rope is its ease of handling — it's very flexible, it's soft, and it doesn't develop the barbs and "fish hooks" like wire rope can. Another benefit is that synthetic rope doesn't store as much potential energy as steel, so the risk of injury due to a rope failure can be reduced. That said, you still want to use a winch damper, put your gloves on, and follow all the correct rigging techniques.

Synthetic rope costs about two-thirds as much as steel over its lifespan, and generally synthetic rope doesn't last quite as long as steel.

Hopefully today you've learned a little bit about the difference between steel and synthetic rope. Ultimately the choice is yours — each has its specific applications. Be sure to take a look at the product literature for important safety tips and more information, and to learn more about our products visit warn.com.