Aluminium handlebars and fatigue - interested in real world experiences

[Llewellyn]

I'm aware that aluminium fatigues over time and I've read about cases where handlebars have failed as a result (and I expect the results would be pretty unpleasant). Most of the cases I've read about have been in race situations where you'd expect gear to be put under more stress than an average rider might put it through.

So I'm interested to hear if anyone has had handlebars fail from fatigue or routinely replaces their aluminium handlebars, and how often. Do you replace them after a certain number of km's or after a certain number of years. Are the cheaper models in a manufacturers range more likely to fatigue than the more expensive bars?

 

[bc_hills]

I'm aware that aluminium fatigues over time and I've read about cases where handlebars have failed as a result (and I expect the results would be pretty unpleasant). Most of the cases I've read about have been in race situations where you'd expect gear to be put under more stress than an average rider might put it through.

So I'm interested to hear if anyone has had handlebars fail from fatigue or routinely replaces their aluminium handlebars, and how often. Do you replace them after a certain number of km's or after a certain number of years. Are the cheaper models in a manufacturers range more likely to fatigue than the more expensive bars?

This is news to me. I've never heard of aluminum handle bars failing due to fatigue.

 

[Night Rider]

Aluminium bars won't fail due to fatigue, they may fail due to corrosion but that would take years of neglect in not checking them when replacing your bar tape.

I had one bike for about ten years and no sign of corrosion on that one, didn't use it on a stationery trainer though (sweat drips).

 

[oronet commander]

I used a 190-g ITM during 6 years (36,000 km) with no problem whatsoever. Nevertheless, when I built my new bike I didn't reuse it and bought a new one just in case it was too old.

Just my 2c...

 

[Martin318is]

Aluminium bars won't fail due to fatigue, they may fail due to corrosion but that would take years of neglect in not checking them when replacing your bar tape.

I had one bike for about ten years and no sign of corrosion on that one, didn't use it on a stationery trainer though (sweat drips).

where did you hear that? Its written as though Aluminium is impervious to failure but bars are under constant work due to road vibrations and leverage stress. It follows quite logically that an aluminium component will eventually fail under load - the only question is how long. I have seen it a number of times - but not in the last 5 years or more. I think this may be because people switch bikes and components a lot more than we did in the 80s or 90s. Also people tend to go to carbon bars if they are trying to get light weight - meaning that there are not really as many ultralight alu bars around as there used to be.

 

[DirtyWorks]

An aluminum bar can fail and have failed. Carbon has eliminated most of the crazy light alloy bars that used to be on the market.

What's left are alloy bars that can last if you are doing recreational road riding. 'cross/dirt road and mountain bike racers should definitely think like their alloy bars/stem have a use limit. Roadies too, but most of them I would guess have gone carbon anyway.

 

[Ruby60]

Some ( maybe 10 ) years ago I was on a ride with my buds. From a dead stop, while starting up, one side of my buds bars broke off!! He was very lucky that he did not crash. Upon examination, it looked like there were little cracks where the indentation was made for cable routing. Famous name bars too. But I have to say that he was 100+ kilograms, and was really putting an effort in.
I think it was a manufacturing defect rather than fatigue though.

 

[hmsgenoa]

Here's a real world (championship) experince for you;

http://losesplendorosos.wordpress.com/2011/02/27/world-championship-89-lyon-alexander-kirichenko/

Kiritchenko pulled his bars apart with about a lap to go, briefly looked at the offending part in disgust, chucked it and continued to a 1.02 or 1.03 still managing to win bronze.

Also found a series of pics from same worlds (Lyon 1989) well worth a look;

http://www.flickr.com/photos/nztony/4858771223/in/set-72157624641851616/

And while you are at it you might enjoy seeing Colin Sturgess lighting up the track (wonder how much the DDR bike was worth in Seoul, my guess is more than the 0.74 second he lost the Bronze by) ;

http://www.youtube.com/watch?v=JAKp6nAdshE

 

[hmsgenoa]

Here's a real world (championship) experince for you;

http://losesplendorosos.wordpress.com/2011/02/27/world-championship-89-lyon-alexander-kirichenko/

Kiritchenko pulled his bars apart with about a lap to go, briefly looked at the offending part in disgust, chucked it and continued to a 1.02 or 1.03 still managing to win bronze.

Also found a series of pics from same worlds (Lyon 1989) well worth a look;

http://www.flickr.com/photos/nztony/4858771223/in/set-72157624641851616/

And while you are at it you might enjoy seeing Colin Sturgess lighting up the track (wonder how much the DDR bike was worth in Seoul, my guess is more than the 0.74 second he lost the Bronze by) ;

http://www.youtube.com/watch?v=JAKp6nAdshE

Incidentally I think the bike design contributed to the failure, with the bars leverage point being closer to the wheel, when riding out of the saddle more effort is required to pull the bike upright after each pedal stroke (it literally feels like the bike is falling sideways), and with those weight trained arms tugging on the bars it's perhaps no surprise they failed. If the bars are fitted conventionally this effect is reduced because they are fixed higher.

 

[The Gnome]

been riding them forever...never had any fail or hardly flex...

 

[ElChingon]

It can all break or fail, doesn't matter what its made out of.

The OP did not state where this info on impervious Aluminium is or came from. Other than rumor and speculation as it always is.

I wouldn't be surprised if someone who owns bike equipment and sells it doesn't start spewing such comments out to scare people to buy new stuff in a way to sell more parts. You might say I've heard such BS comments from some less than desirable retail outlets of bike components and bikes.

As long as you take care of it and keep an eye on all your equipment you should be fine. Take care as in take it apart and inspect at least once a year if you ride regularly and store the bike when not in use away from the elements or any extreme or harsh conditions. Some think this is too much and well it might be but its your body/life/family that will take the hit if you don't, and a measly helmet is not a life preserver if anything happens, sure it protects your noggin but if your work involves an extremity which just broke or worse, you're going to pay for it.

The only exception is if something has a recall, then you should replace it asap, usually for free or just an exchange.

Almost forgot, I have both carbon and Aluminium bars all fine, but the carbon bars are a bit more comfy.

 

[avanti]

I saw a female sprinter (from the Netherlands as I recall) in the 1986 world championships break her bars and landed up on the concrete - fortunately she was able to continue in the competition.

As an aerospace engineer I will not buy bars (or other stressed components) made from aluminum alloy 7075-T6 which is susceptable to stress fatigue.

I also have some aerobars but have not used then because the clamp surface is serrated and I am concerned it would damage my bars.

 

[BroDeal]

Best practice used to be to replace your bars after a year of racing...or two years, I forget which. It might have been bar manufacturers that came up with that.

I have never had a problem. But I don't like using my resistance trainers and rollers, don't have caustic sweat, and live in a low humidity environment, so corrosion is not an issue.

I also once put twenty thousand miles on a bar with indentations from a clip-on aero bar. It held up fine.

Carbon bars after minor crashes and falls worry more than aluminum.

 

[Alex Simmons/RST]

where did you hear that? Its written as though Aluminium is impervious to failure but bars are under constant work due to road vibrations and leverage stress. It follows quite logically that an aluminium component will eventually fail under load - the only question is how long. I have seen it a number of times - but not in the last 5 years or more. I think this may be because people switch bikes and components a lot more than we did in the 80s or 90s. Also people tend to go to carbon bars if they are trying to get light weight - meaning that there are not really as many ultralight alu bars around as there used to be.

Indeed. I have personally had alu road bars break off while riding (maybe 10 years ago now), which ended up with my left hard suddenly down by the front wheel axle. A little disconcerting. Fortunately I was on the uphill section of a hilly ride and remained upright.

Managed to ride to my LBS after that to get a new set though.

My track bars are nitto steel. They ain't gunna break anytime soon

 

[42x16ss]

It can all break or fail, doesn't matter what its made out of.

The OP did not state where this info on impervious Aluminium is or came from. Other than rumor and speculation as it always is.

I wouldn't be surprised if someone who owns bike equipment and sells it doesn't start spewing such comments out to scare people to buy new stuff in a way to sell more parts. You might say I've heard such BS comments from some less than desirable retail outlets of bike components and bikes.

As long as you take care of it and keep an eye on all your equipment you should be fine. Take care as in take it apart and inspect at least once a year if you ride regularly and store the bike when not in use away from the elements or any extreme or harsh conditions. Some think this is too much and well it might be but its your body/life/family that will take the hit if you don't, and a measly helmet is not a life preserver if anything happens, sure it protects your noggin but if your work involves an extremity which just broke or worse, you're going to pay for it.

The only exception is if something has a recall, then you should replace it asap, usually for free or just an exchange.

Almost forgot, I have both carbon and Aluminium bars all fine, but the carbon bars are a bit more comfy.

+1

If you look after your bars, then you shouldn't have any real issues unless there is a design or manufacturing defect. Just remember to rinse off any salt/old glue etc and check for wear and cracks when you change your bar tape (every 2 - 3 months) and especially after a crash or traveling with your bike and you should be fine.

Look after your equipment and it will look after you

 

[rustychisel]

It isn't that simple. Sometimes things just break, and those subject to fatigue will break at some time or other. It usually isn't any fun...

These broke on the velodrome at about 50kmh at the end of a flying 200. As I eased up and slowed my legs I was pushing down on the bars and the left hand side just folded down like cheese. I was able to lift my left hand, steer with my right and stop without mishap. If they'd broken when I was absolutely honking it would have been a different story, obviously, though I've no doubt they broke as a result of the efforts they'd been subjected to. I was just lucky the crack which lead to failure propagated at the top of the bars. [these were old bars, been on my bikes for about 20 years, but never abused, never cracked].