Batten Systems

Comprehensive mainsail batten configurations, materials, hardware, and furling system compatibility.

Batten Types and Configurations

Full-Length Battens

Property	Specification
Length	Leech to luff (100% of sail chord)
Roach support	Maximum—enables large roach designs
Shape control	Excellent—maintains designed airfoil
Compression load	Carried directly to mast via batten cars
Weight	Heavier than partial battens
Hardware requirements	Batten cars or receptacles at luff

Applications: Performance cruising, racing, large roach mainsails

Typical Count by Boat Size:

Boat LOA	Sail Area (m²)	Recommended Full Battens
<30ft	<30	3-4
30-40ft	30-50	4-5
40-50ft	50-80	5-6
>50ft	>80	6-7

Partial (Short) Battens

Property	Specification
Length	Leech only (typically 25-40% of sail width)
Roach support	Moderate—prevents leech flutter
Shape control	Basic leech support only
Weight	Lighter than full-length
Hardware requirements	Simple pocket closure, no luff fittings

Applications: Traditional cruising, budget builds, backup sails

Typical Count: 4-6 battens regardless of boat size

Vertical Battens (Furling Systems)

Property	Specification
Orientation	Parallel to luff (perpendicular to traditional battens)
Length	Variable, typically 1-2 meters
Purpose	Maintain roach and prevent leech flutter during furling
Car requirements	None—battens run vertically
Furling compatibility	Required for in-mast, recommended for in-boom

Critical Rule: In-mast furling mainsails can ONLY use vertical battens due to the mast cavity constraints.

Applications:

In-mast furling (mandatory)
In-boom furling (optional but recommended)
Stack-pack/lazy-jack systems

Typical Count: 3-5 vertical battens

Special Considerations:

Must avoid overlapping inside mast cavity (prevents jamming)
Shorter lengths preferred to reduce twist/jam risk
Proper tension critical to prevent flicker during furling

Batten Materials and Construction

Fiberglass (Standard)

Property	Value
Stiffness	Moderate to high (depending on layup)
Durability	High—resistant to repeated flexing
Repairability	Field repairable (can be cut/sanded)
Weight	Baseline reference
Impact tolerance	Good—bends before breaking
Cost	Economy to mid-range

Brand options: Bainbridge, RWO, Challenger

Carbon Fiber

Property	Value
Stiffness	High to very high
Weight	40-50% lighter than fiberglass
Durability	High under normal loads, brittle on impact
Tuning	Precise stiffness profiles available
Repairability	Difficult—professional replacement recommended
Cost	Premium (2-3x fiberglass)

Brand options: Forespar, Hall Spars, CST Composites, C-Tech

Best for: Racing, weight-critical applications, large boats (45ft+)

Hybrid (Carbon/Fiberglass)

Property	Value
Stiffness	High
Weight	~20-30% lighter than pure fiberglass
Impact tolerance	Better than pure carbon
Cost	Mid-range

Best for: Performance cruising, club racing

Batten Taper Types

Tapering controls sail draft position and prevents hard spots in the sail.

Standard (Flex) Taper

Property	Specification
Taper direction	Thin at luff → Thick at leech
Draft position	40-45% aft of luff (optimized)
Application	Partial battens, general purpose full battens
Characteristic	Soft tip allows smooth bend, prevents hinging

Purpose: Prevents “hard spots” where batten ends—critical for partial battens

Compression Taper

Property	Specification
Taper profile	Straight-line thickness reduction towards luff
Draft position	Moves forward under compression load
Application	Full-batten racing mainsails, jibs
Characteristic	Designed for high-load applications

Reverse Compression Taper

Property	Specification
Profile	Full thickness forward, tapers aft (~15% length), then increases again
Draft position	Locked forward, maintains flat entry
Application	Heavy air racing, upwind performance
Benefit	Flatter entry even as wind strength increases

Untapered (Uniform)

Property	Specification
Profile	Constant thickness throughout
Draft position	~50% (natural mid-point)
Application	Vertical battens, some budget builds
Trade-off	Less control over draft position

Batten End Fittings and Hardware

Leech End Fittings

Standard End Caps

Type	Material	Application
Dome cap	Nylon/Acetal	Standard cruising
Low-profile cap	Nylon/Acetal	Racing (reduced drag)
Rocket tensioner	Carbon/Acetal	Performance/racing

Rocket Tensioner System (RBS, C-Tech):

Aerodynamic bullet-shaped end cap
Integrated tension adjustment
Quick-release mechanism
Available in carbon fiber or acetal plastic

C-Tech Leech End Tensioners (sizes):

5.5 x 16mm (small dinghies)
7 x 16mm (keelboats 20-30ft)
8 x 19mm (boats 30-40ft)
10 x 25mm (boats 40-50ft)
17 x 27mm (large boats 50-60ft)
20 x 32mm (60ft+)

Luff End Fittings (Full-Batten Only)

Batten Receptacles (The “Turtle Shell”)

Luff-end fittings that secure full-length battens to the mast or batten cars. The following systems are the industry standard for durability and adjustability.

Bainbridge A-Series (Standard)

Economic and durable solutions reinforced nylon construction. Compatible with Allslip slides.

Model	Batten Type	Max Size	Features	Application
A300BK	Flat	30 x 6.5 mm	Screw adjustment, 40mm cavity	Medium/Small boats
A303	Flat	45 x 7 mm	Screw adjustment, 47mm cavity	35-45ft Cruisers (Beneteau OEM)
A306BK	Round	16-20 mm	Heavy duty round receptacle	Large cruising monohulls
A082	Micro	8 mm	Basic fixed end	Dinghies / Leech battens
A305BK	Round	6-12 mm	For pull-braided round battens	Small-Medium cruisers

Bainbridge Sailman (U-Series)

High-end system with integrated tensioners and enclosed mechanics.

Model	Series	Compatibility	Features
U01540	Sailman 25	30 x 5.2 mm	M10 thread, integrated tensioner
U01530	Sailman 35	Universal	Fixed (no adjust), M10 connection
U01531	Sailman 35	Universal	Metal fork adjustment, M10 thread
U01535	Sailman 35HD	Heavy Duty	Reinforced metal internals, M10/M12
U01520	Sailman 55	Maxi System	M10 thread, offshore structural

Rutgerson 1490 & 1530 System

The 1490 “Limpet” protection is designed to interface perfectly with 1530 series battcars.

Model	Material	Fitment	System Match
1490	White Nylon	45 x 5 mm	Std. 24-33ft
1490-1	Composite	45 x 5 mm	Cut-to-length for 1530 Swivel
1490B	Black Nylon	45 x 5 mm	Std. 25-33ft
#1595	Heavy Duty	Custom	45ft+ Cruising

1530 Battcar Connection:

1530-11-03: Swivel (Via 1490-1 cutback)
1530-11-15: Fork (Standard connection)
1535-11-15: High Load Fork (785kg BL)

Ronstan PNP155 (Vernier Adjuster)

Precision “Caliper-style” adjustment system for racing.

Mechanism: Worm-drive vernier scale for fingertip tensioning under load.
Weight: 148g (Ultra-light).
Fitment: Flat (22x10mm) or Round (13mm).
Mount: Webbing slot for luff slide attachment.

SDA Series (Round Batten Specialists)

Simple, robust aluminum/composite housings for round battens. M10 Thread.

Model	Batten Ø	Position	Application
SDA 8-12	8-12 mm	Luff/Leech	Small/Medium cruisers
SDA 12-16	12-16 mm	Universal	40ft+ Round battens
SDA 16-20	16-20 mm	Heavy Duty	50ft+ Offshore

Selden FA Series (Adjustable Receptacles)

High-precision adjustable receptacles with dual-direction tuning and index scales.

Model	Batten Compatibility	Max Size	Interface	Features
FA-22	Flat / Round	Flat: 9.5x23mm Round: 10mm	M10 Thread	Dual-direction precision adjust, graduated scale (134x62mm)
FA-30	Flat / Round	Flat: 6.5x31mm Round: 12mm	M10 Thread	Dual-direction precision adjust, graduated scale (134x72mm)

Performance & High Load Systems

Karver 1612T Ti: Titanium M12 connection for Superyachts. “Fuse” system protects mast track.

Installation Options (Non-Hardware)

Type	Description	Application
None (Customer Install)	No pre-installed receptacle	Budget builds, DIY installations, customer supplies own hardware
Webbing Closed	Permanently sealed batten pocket	Standard cruising, simplified construction, no tension adjustment

Thread Options for Adjustable Systems:

1612T M12 Ti Screws (titanium, lightweight)
SDA (Selden Adjustable) systems:
- 8-12mm (#105675 leech, #105685 luff)
- 12-16mm (#105674 leech, #125684 luff)
- 16-20mm (#105668 leech, #105677 luff)

Batten Pocket Construction

Pocket Finishing Options

Closure methods for batten pocket openings at the leech end.

Finishing Type	Description	Durability	Cost	Best For
Lashing + Velcro Cover	Webbing lashing with Velcro protective flap	Medium	Economy	Cruising sails, easy batten removal
Lashing + No Cover	Exposed webbing lashing (traditional)	Medium	Lowest	Budget builds, traditional aesthetics
Velcro Insert	Internal Velcro closure insert	High	Standard	Most common, good balance of access/security
Elastic Band	Elastic loop closure system	Medium	Economy	Light-air sails, frequent batten changes
Webbing Closed	Permanently sealed pocket end	Highest	Standard	Fixed battens, maximum durability
Velcro Flip-Flop	Double-sided Velcro flap system	High	Mid-range	Racing, secure closure with easy access
Side Insert	Side-entry pocket opening	Medium	Standard	Alternative access method

Batten Pocket Width Specifications

Pocket width must accommodate batten dimensions plus clearance for insertion/removal.

Batten Width	Recommended Pocket Width	Typical Application
10-15mm	60-70mm	Dinghies, small keelboats, vertical battens
15-20mm	70-80mm	Keelboats 25-35ft, beach cats
20-25mm	80-90mm	Cruising boats 35-45ft
25-30mm	90-100mm	Large cruising/performance boats 45ft+
30-40mm	100-120mm	Grand Prix racing, custom applications

Note: Add 50-55mm to batten width for comfortable pocket width. Wider pockets ease batten insertion but may allow batten movement.

Batten Models and Specifications

Fiberglass (E-Glass) Battens

Standard workhorse battens for cruising and club racing.

RBS E-Glass Series

Width	Available Thicknesses	Typical Application	Taper Options
10mm	11 thickness options (1-6mm range)	Dinghies, one-design jibs/mains	Flex (F), Compression (C), Non-tapered (NT)
12mm	11 thickness options	Small keelboats, dinghies	Flex, Compression, Non-tapered
15mm	11 thickness options (2-7mm range)	Beach catamarans, cruising 25-35ft	Flex, Compression, Reverse Compression (R)
19mm	11 thickness options (3-8mm range)	Boats 30-45ft, compression/leech battens	All taper types
25mm	11 thickness options (4-8mm+ range)	Large boats 40ft+, high-load applications	All taper types

RBS Model Code Example: E19230/100F

E = E-Glass material
19 = 19mm width
230 = 0.230” (5.8mm) thickness
100 = 100cm order length
F = Flex taper (for leech battens)

Generic Fiberglass Battens

Profile	Common Sizes (W x T)	Applications
Flat Rectangular	9x2.5mm, 18x2mm, 24x2.5mm, 30x4.5mm	Standard cruising battens
Elongated Hexagon	10x3mm, 12x4mm, 14x5mm, 16x6mm, 20x8mm	Performance cruising
Imperial Sizes	3/8” x 0.100-0.140”, 5/8” x 0.110”, 1” x 0.113”	North American market

Carbon Fiber Battens

RBS Carbon Bar (T-700 Series)

High-modulus aircraft-grade carbon for maximum stiffness and weight savings (up to 50%).

Width	Available Thicknesses	Weight Savings vs E-Glass	Application
10mm	Multiple options	~50%	Racing dinghies, high-performance catamarans
15mm	Multiple options	~50%	Performance keelboats 25-35ft
19mm	Multiple options	~50%	Racing boats 30-45ft
25mm	Multiple options	~50%	Grand Prix 40-60ft
38mm	Multiple options	~50%	Maxi yachts, extreme high-load applications

Carbon Model Code Example: CB25280/120C

CB = Carbon Bar material
25 = 25mm width
280 = 0.280” (7.1mm) thickness
120 = 120cm order length
C = Compression taper

Generic Carbon Battens

Profile	Common Sizes	Features
Flat Carbon	10mm, 14mm, 15mm, 19mm, 20mm, 25mm, 30mm widths	Standard high-performance
Hollow Round	Various diameters	Ultimate weight savings
Rectoid	Custom dimensions	Optimized stiffness profiles

Batten End Configurations

End Type	Description	Adjustment Method	Typical Application
Standard Cap	Simple dome or flat end cap	None (tensioned at luff)	Budget cruising
Rocket End	Integrated rocket-style tensioner at leech	Flathead screw adjustment	Racing, performance cruising
Compression Fitting	Spring-loaded luff end	Compression spring	Full-batten systems
Fixed Sewn	Batten sewn into pocket permanently	None	Traditional cruising

Rocket Tensioner System (RBS/Forespar)

Purpose: Allows leech-end batten tensioning for precise sail shape control.

Specifications:

Screw: 1.750” (44mm) stainless steel flathead
Adjustment Range: ~1.250” (32mm)
Weight: Lightweight composite construction
Installation: Batten trimmed 2” (50mm) shorter than pocket length
Attachment: Spectra loop sewn into sail pocket

Compatible Batten Sizes:

15mm x 7.6mm (standard)
Compatible with RBS foam battens and fiberglass/carbon battens of similar dimensions

Adjustment Procedure:

Back off screw ~1/2” (13mm) before insertion
Insert batten into pocket
Tighten screw with flathead screwdriver until pocket wrinkles disappear
Important: Ease tension when sail not in use to prevent sailcloth stretch

Batten Selection by Width and Material

Boat Size	Mainsail Type	Batten Width	Material Recommendation
<25ft	Standard cruising	10-12mm	Fiberglass
25-35ft	Cruising	15-19mm	Fiberglass or Hybrid
25-35ft	Performance/Racing	15-19mm	Carbon
35-45ft	Cruising	19-25mm	Fiberglass or Hybrid
35-45ft	Performance	19-25mm	Carbon
45-60ft	Cruising	25-30mm	Fiberglass (heavy duty)
45-60ft	Racing	25-38mm	Carbon
>60ft	Any	30-38mm	Carbon (custom profiles)

Batten Tension and Adjustment

Proper Tension Guidelines

Tension Level	Visual Indication	Result
Too loose	Vertical wrinkles along pocket	Batten flicker, poor shape control
Correct	Smooth pocket, no wrinkles	Designed sail shape achieved
Too tight	Horizontal tension lines, stressed fabric	Sail deformation, reduced performance

Best Practice: Tension just slightly beyond the point where wrinkles disappear. When in doubt, err on the side of slightly less tension.

Adjustment Methods

Method	Mechanism	Application
Compression spring	Spring-loaded luff fitting	Standard full-batten systems
Rocket tensioner	Integrated screw adjustment at leech	Performance/racing
Hook and loop	Velcro straps	Light-air sails, vertical battens
Screw adjustment	Threaded fitting with lock nut	Racing (precise tuning required)
Fixed (non-adjustable)	Sewn-in, no adjustment	Budget builds, partial battens

Batten Flicker Prevention

Batten flicker occurs when battens vibrate or “buzz” inside pockets, especially in vertical batten furling systems.

Primary Causes and Solutions

Cause	Solution
Insufficient batten tension	Increase tension to eliminate pocket wrinkles
Batten too soft for wind conditions	Replace with stiffer batten
Pocket closure not secure	Ensure Velcro/lashing is fully closed
Sail stretch (aged sail)	Re-cut sail or replace if beyond service life
Incorrect furling technique	Furl with proper outhaul tension, head into wind

Vertical Batten Specific (In-Mast/In-Boom)

Issue	Prevention
Batten overlap/twist inside mast	Use shorter battens that cannot overlap
Uneven furling	Maintain consistent outhaul tension while furling
Batten pocket chafe	Add internal Taffeta lining to pockets
Leech flutter	Ensure battens extend fully to leech (support full roach)

Batten Hollow (Mandrel) Systems

Batten hollow refers to the space carved into the sail’s luff area to accommodate the batten when furled into a boom or mandrel.

In-Boom Furling Requirements

Requirement	Specification
Hollow depth	Must accommodate batten thickness when rolled
Mandrel diameter	Larger mandrel = easier furling with battens
Batten position	Battens must align with mandrel grooves (if grooved system)
Number of battens	Typically limited to 3-5 due to furling complexity

Special Consideration for In-Boom + Full Battens:

Not all in-boom systems support full-length battens
Grooved mandrels (e.g., Leistefurl, Reckmann) designed for full battens
Hollow must be precisely cut to prevent batten binding during furling

In-Boom + Reefing Integration

System Type	Batten Compatibility	Notes
Standard in-boom	Vertical battens only	Full-length horizontal battens incompatible
Grooved mandrel	Limited full-length battens (3-4)	Battens must align with mandrel grooves
Hybrid (in-boom + slab reef)	Vertical battens + partial horizontal	Vertical for furling, short horizontal for shape

Furling System Compatibility Matrix

Batten Type	Slab Reef	In-Mast Furling	In-Boom Furling
Full-length horizontal	✅ Optimal	❌ NOT compatible	⚠️ Only with grooved mandrel
Partial horizontal	✅ Compatible	❌ NOT recommended	✅ Compatible
Vertical	✅ Compatible	✅ REQUIRED	✅ Optimal

Batten Stiffness Profiles

Standard Graduation (Top to Bottom)

Batten Position	Relative Stiffness	Purpose
Top batten	Stiffest	Controls headboard area, maximum twist control
Upper-mid battens	Progressive reduction	Smooth airfoil transition
Lower-mid battens	Medium stiffness	Balance between shape and flex
Bottom batten	Softest	Allows boom movement, prevents hard spot at foot

Stiffness by Wind Conditions

Application	Batten Profile	Result
Light air (<10 kts)	Softer overall	Rounder, more powerful sail shape
Heavy air (>20 kts)	Stiffer overall	Flatter sail, reduced heeling
All-around	Progressive standard	Balanced performance

System Integration and Best Practices

Batten Car Spacing

Boat Size	Recommended Car Spacing
<35ft	450-600mm between batten cars
35-45ft	500-700mm between batten cars
>45ft	600-800mm between batten cars

Note: Spacing affects sail shape control—closer spacing = better shape retention

Replacement and Maintenance

Component	Replacement Interval	Signs of Wear
Fiberglass battens	5-8 years	Permanent set (won’t straighten), delamination
Carbon battens	7-12 years	Visible cracks, splintering at ends
End fittings	3-5 years	Cracked plastic, stripped threads
Batten pockets	5-10 years	Torn fabric, failed Velcro, chafe holes
Batten cars	8-12 years	Seized bearings, worn wheels, cracked composite

Certification and Standards

Racing Compliance

Standard	Batten Requirements
World Sailing	No restrictions on batten type/material
IRC	Batten configuration affects rating
ORC	Measured batten count and length affect VPP
One-Design Classes	Class-specific rules (consult class association)

Quick Reference: Batten Selection by Application

Sailing Profile	Batten Type	Material	Taper	End Fitting
Cruising (standard)	Partial	Fiberglass	Flex	Standard cap
Performance cruising	Full-length	Fiberglass or Hybrid	Compression	Rocket tensioner
Club racing	Full-length	Hybrid or Carbon	Compression	Rocket tensioner + receptacles
Grand Prix racing	Full-length	Carbon	Reverse compression	Carbon rocket + carbon boxes
In-mast furling	Vertical only	Fiberglass	Untapered or slight taper	Velcro or elastic closure
In-boom furling	Vertical	Fiberglass	Untapered	Velcro closure
Budget build	Partial	Fiberglass	Flex	Webbing closed