Guard Wire Inspection and Replacement Made Simple
Keeping Your Guard Wires Shipshape—A Step-by-Step Guide
Guard wires—also called guard rails or lifelines—are key safety features on yachts and boats. They run through the stanchions between the pulpit and pushpit, helping to prevent anyone from accidentally going overboard.
Like all safety gear on your boat, guard wires need regular checkups. If there’s any sign of wear or damage, they should be replaced straight away.
While insurers are focusing more on the condition of standing rigging, guard wires aren’t under quite as much scrutiny—for now. But if you've bought a second-hand yacht, it’s wise to inspect both the standing rigging and guard wires closely, since they're all made from similar materials and share the same wear concerns.
Swapping out guard wires might seem like a big task, but with a bit of know-how (and maybe a hand from the Jimmy Green Rigging Team), it’s totally doable.
Ordering New Guard Wires
You can order pre-swaged wires—ready to install—as long as your stanchion holes are at least 8mm in internal diameter. There’s wiggle room when it comes to length thanks to adjustable rigging screws or lashings, so minor measuring mistakes won’t derail the job.
Turnbuckles are generally supplied set to two-thirds open for the best adjustment range. If your stanchion holes are too tight for swaged terminals, you’ll need one swaged end and the other end finished with a mechanical (DIY) terminal. Sta-Lok and Petersen make solid, easy-to-use options here.
Guard Wire Checklist
Here’s how to get started:
1. Initial Assessment
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Check the entire system: stanchions, bases, pulpit/pushpit, deck fixings, and alignment.
- Look for signs of leaning or tension fatigue.
- Standard stanchions are 610–900mm tall and spaced roughly 2m apart.
- Most boats use two wires: an upper at full height (~600mm) and a lower mid-height.
- Keep spans short to prevent damage from impacts.
- If you have gates, ensure they’re properly supported and tensioned.
If no gate is installed, wires should run continuously with tensioners at the aft (pushpit) end.
> Tip: Guardrail webbing is a comfortable alternative to wire, especially where crew may lean frequently. Guardrail netting adds security and keeps small items—or people—from slipping through.
Fender lines are often tied to guard wires. It’s not ideal, but if you must, tie them close to a stanchion to reduce strain.
2. Wire Type: Coated or Bare?
- PVC-coated 1x19 stainless steel wire feels softer and looks tidy but may hide corrosion.
- Bare stainless wire makes inspection easier but isn’t as forgiving to the touch.
- 4mm and 5mm wire are most common for yachts under 12m. Consider 6mm for yachts over 15m.
- Avoid flexible constructions like 7x7 or 7x19 for lifelines—they’re less durable.
3. Detailed Inspection
Look out for:
- Rust or corrosion where wires exit the PVC coating.
- Damage or kinks where wires pass through stanchions.
- Deformation in plain wires.
- Signs of chafe or bending near fittings.
Also inspect:
- Stanchions and gates—Are they bent, loose, or worn?
- Stanchion bases—Are they solidly fixed?
- Pulpit/pushpit welds—Any cracks or weaknesses?
- Lashings/lanyards—Are they tight, UV-resistant, and in good shape?
4. Plan for Any Changes
Thinking of switching fittings or cleaning up your rigging layout? Now’s the time. Eliminate unnecessary shackles or components, and choose optimal fittings like fork terminals where possible. For tensioners, you’ve got options: bottle screws, rigging screws, adjustable forks, or lanyards.
5. Take Photos
Snap detailed photos of everything—especially any areas you’re unsure about. They’ll help you later when fitting the new wires and can guide the rigging team if you need advice.
6. Mark the Tension
If you adjust any fittings, mark their positions or take photos so you can return them to the same setting before measuring for new wires. New wires are typically made to length based on these settings—with turnbuckles set around two-thirds open.
7. Think About Improvements
Before placing an order, consider if there’s anything you want to upgrade or tweak. A more efficient fitting or a smarter layout might make things easier in the long run.
Final Step: Sizing and Ordering
Once you’ve confirmed:
- Wire diameter
- Approximate length
- Fitting types (fore and aft)
You’re ready to order online or ask the Martin Leaning Rigging Team to put together a set for you.
And don’t forget—a good pair of callipers is your best friend when it comes to measuring components accurately.