Durability of AV oversuit

[PeteHall]

Last night, I noticed that my AV suit has split along the right thigh. Nothing unusual there, you might say, but I feel like I've hardly used it...

I bought an AV Midroi and a Warmbac 'Digger' just before Christmas 2021. Since most of my caving since then has either been digging (wearing the Warmbac, or another old oversuit), or diving (wearing a wetsuit), or diving and digging (wearing a wetsuit and the Warmbac), the AV hasn't had much use; it's probably only been underground 10 times.

The knees are fine, the elbows are fine, the crotch is fine, but now, the thigh has a 10" hole in it. The Warmbac meanwhile, which has seen far more abuse and is definitely showing signs of wear, has no such problem. Perhaps because the Warmbac does not have a seam on the outside of the leg.

Has anyone else experienced premature failure on an AV suit, as described?

This is my first AV suit and it's very comfortable, but if they fall apart so quick, I'm not sure I'll be buying another...

 

[Edwardov]

When you buy a new oversuit you should dunk it in water and dry it out several times just like new rope. The reason is that the stitching is exposed when new, by drying it out multiple times everything tightens up and the stitching recesses into the fabric more so it isn’t as exposed to wear and tear.

 

[cap n chris]

Yes, Pete. My last two AVs both exhibited this. It is likely a weakness of the design and represents a significant wear-surface, prone to failure as you describe. My AVs have been used digging and don't last long, certainly less than a year. I have returned to using a Warmbac for digging now.

 

[PeteHall]

When you buy a new oversuit you should dunk it in water and dry it out several times just like new rope. The reason is that the stitching is exposed when new, by drying it out multiple times everything tightens up and the stitching recesses into the fabric more so it isn’t as exposed to wear and tear.

If that works, it is certainly a top tip! Not something I'd ever though about.

 

[paul]

I've been using an AV suit for several years and so far a seam or tow has ripped a small amount between the knees down to rubbing together when I had kneepads on and the bottoms tucked into my wellies and the large black patch on the arse went long ago but generally it seems fair wear and tear for the amount of use it has had and definitely no worse than many other oversuits I have used over the years.

 

[mrodoc]

I have two AV suits. One I keep for serious caving (when I do any nowadays) and the other for digging. The digging one has lost the arse panel as described above and I have patched the elbows and knees a couple of times but it is wearing well now. The double layers on elbows and legs once they get holey tend to hold water and dirt so on the digging suit I have now slit the base to allow drainage . However AV make the most comfortably fitting suits I have ever worn - by far. I think the amount of grovelling in British caves probably wears them out faster than caves visited by our continental cousins. I think there is a compromise between flexibility and durability. Warmback suits are durable and more waterproof but don't fit so well unless you fit them"

 

[hannahb]

Yes Pete - it seems that when they were first common on the UK market they were better built and lasted longer. Replacement ones seem to wear out, especially tear, really quickly. It's the same issue as with so many other oversuits unfortunately. Perhaps it's a change in the fabric or construction to avoid massive price increases? We've got an old one at home that we could compare to a recent one if of interest, in terms of the fabric at least.

 

[cap n chris]

LOL @ Mrodoc "...don't fit so well unless you fit them". Yarp.

 

[LadyMud]

I believe this used to be an AV suit

Repairing oversuit?

My oversuit is in tatters and is in dire need of repair. It is barely a suit at this point but I am caving in Ardeche, Slovenia, Switzerland, France and possibly Austria too in the next 6 months... plus a month of hard Dales caving. I am determined to make my suit last until September, or even...

ukcaving.com

 

[badger]

I have a 2 piece AV suit which must be in excess of 5 years old, admittedly not living a caving area it sees a lot less use than most, but I have not had any issues at all with it. the previous AV suit was an all in one, and again must have been in use for over 5 years.

 

[HeathJ]

I've been using an AV for around 6 years. For the first three is was pretty hole free (normal sport caving in the dales most weekends). After that the fabric on the reinforced areas started to go. A recent trip to wales seems to finally have killed it with a 6 inch tear on each shoulder! I suspect the fabric has finally worn out. But considering that's probably 200 trips I'm not too upset about it!

This all said, I've noticed that people in our club with suits bought in recent years do seem to be having far more issues with wear and tear. Wouldn't be surprised if there has been a slight change in material.

 

[mrodoc]

LOL @ Mrodoc "...don't fit so well unless you fit them". Yarp.

Procrustes mate, Procrustes!

 

[topcat]

I had one fail due to catastrophic delamination of the inner PU layer. I could have gone to a job interview wearing the suit as it was externally pristine !

I have it still and one day intend to take it apart and use it as a pattern to make another...

 

[Steve Clark]

I also had a red one totally delaminate without much wear on the outside. I’ve stopped using it before it totally falls apart and I am planning on saving it for a lightweight protective layer over a wetsuit (Diccan / Rowten through trip).

My recent replacement (blue) seems to have a better PU layer.

I think you just have to accept the lightweight and flexible nature of the AV suits has some disadvantages. £1-2 a trip I guess. Which is small in the scheme of diesel etc in a full caving day.

Seems to be far better economics than my new Santi drysuit, which by my rough maths seems to average out at £10 every time I move the zip.