Long story short…I wrecked hard last night. I was in a paceline doing around 30 MPH. The front guy didn’t call out a very, VERY large pothole. I hit it. When I hit the hole the left side of my Zipp B2 Carbon bars snapped like a twig. This was not to due to any impact of any kind. The break was caused by the energy transfer from the tire/wheel/fork/headset/stem to the handlebars. Needless to say, I kissed the pavement with my shoulder, hip, elbow, and head. I was just wondering if anyone has an experience similar to this. Also, you think Zipp would be interested in hearing more about this situation. I have some pretty good digital pictures I could share. All the damage to me and my bike are on the right side, and the left side is perfect…that is except the fact that the left side of my handlebars are snapped off about 1 in past the stem. I am most definitely not looking for any handouts from Zipp. My body hurts quite a bit, but I don’t think it would be worth a Sub Zero or anything. They are currently $200 bars. I would guess that they would want to make sure this malfunction won’t happen very often.
If I were Zipp I’d want that bar back for analysis and happily give you a replacement. Talk to your LBS (or whoever you bought it from, if online).
If I were you, I wouldn’t want another carbon bar - but I’d still talk to my LBS about the breakage. If Zipp does offer a replacement, take it and sell it.
If I can ask without seeming offensive in your time of bodily pain, did you use a torque wrench on the stem faceplate when you tightened it? I know of a couple people that have snapped carbon bars in similar locations (of various makes/manufacturers), and they were all people who used the phrase “I just tightened it until it was snug.”
I hope you are healing up ok. I am a rep for Zipp, but I wouldn’t even start to make a call on warranty, not warranty, only the factory guys can do that. I would suggest taking your bars back to your local dealer and letting them handle it from there.
The B2 is now called the contour.
Here are a couple of things I always go over in my clinics on bars:
Always use a torque wrench (not saying you or your shop didn’t)
Carbon bars are stronger than aluminum bars
I personally change my bar every two years. The bar takes a ton of impacts and stress while you are riding, especially if you are a bigger guy. (I’m 6’4 and 210 lbs)
Just looking at a bar after and impact and not seeing any cracks doesn’t mean it isn’t broken. (again, not saying this is the problem in your case)
I have never personally seen a broken Zipp bar and I have sold a ton of them. (this doesn’t help you, you have had a good close view of one!)
All handlebars break (carbon and Aluminum)
When I was still racing and riding 8-10k miles a year, I replaced my bar every year. (aluminum bars at the time) Just because stuff isn’t broken doesn’t mean it isn’t worn out. I replace my helmet every year as well.
Again, good luck. If you want to contact Zipp directly there is a chat feature on the website, or the customer service line is 800.472.3972. I would strongly suggest going through you local dealer however, especially if you bought the bars from them.
When I was still racing and riding 8-10k miles a year, I replaced my bar every year. (aluminum bars at the time) Just because stuff isn’t broken doesn’t mean it isn’t worn out. I replace my helmet every year as well.
Don’t hold me to this, but I think it is printed on the bar. I haven’t actually installed one in close to a year, so I can’t remember the exact number. If you have one and need the torque I am sure the customer service guys can get it for you, or look in the section that is clamped.
Thank you very much for your response. Zipp makes high quality stuff. I know that. I am not upset with them or their product. Stuff like this happens in cycling. Do you think they would want the bars for inspection purposes?
why should folks change their carbon bars every year? if they are installed correctly, and have not been damaged, there is no reason a carbon bar should fail. properly manufactured carbon composites don’t “fatigue” like aluminum alloys.
if i truly follow this advice, i sure as hell don’t want to be flying around in any airbus aircraft or 777 aircraft. they have tons of carbon composite parts just waiting to catastrophically fail …
Ouch! Sorry to hear. I just recently replaced my entire “front end” after a carbon part failure, installed to spec as well. New bars (Deda AL) stem (Deda) and fork (STEEL steerer) and internal headset (why not) Gained a whopping 80g in weight, some stiffness and a whole lot of piece of mind…
Carbon fiber doesn’t fatique. Carbon composites may or may not fatique (in a strict engineering sense) depending on the construction used and the other materials, resin etc). Any carbon structure will have a service life whereby the accumulated damage will result in failure at some point. Some types of damage can be from UV light wear, scrapes, scratches, imacts strong enough to break some fibers but not high enough to cause failure, etc. Some of this will be visible on inspection, some wont.
I’m certain carbon fiber aircraft components are subject to regular inspection. I’m not sure if they have a set service life but I suspect critical components such as helicopter rotors have to be replaced even if they pass an inspection.
For me it is simple. I am a bigger guy who rides a lot, and used to ride a lot more. My replacing my bar every year was something I did when I was riding Al bars over 8k miles a year. Now that I ride half that, I still replace my bar every two years. Even though I agree with you about carbon fatigue, I personally don’t feel that is applicable to the real world. I have no scientific evidence to back this up. However, over the course of two years, I have hit countless potholes that I didn’t see for one reason or another, and jumped more than my fair share of railroad tracks. I feel like all of this is probably hard on a bar. Also, my bike has probably fallen over at least once or twice.
In airplane construction, I would think that the loads are a little more controlled than the real world of bicycle riding. Airplanes don’t fall over, and most of the carbon componets are shielded from the outside world. I know this isn’t always the case. Also, I am sure that the carbon components of most airplanes are pretty overbuilt. Most carbon bike parts are just as strong as they need to be to keep weight as low as possible.
I personally just get piece of mind from changing parts that I know have had a hard life on my bike. Yes, I know I am “in the industry” and it doesn’t cost me as much as if I were not, but I practice this in other parts of my life as well where I don’t get favorable pricing. It costs a few hundred extra dollars here and few there, but this is an expensive sport. Not as bad as some I am sure.
If you don’t want to replace your bars don’t. That is why I try to make it clear it is something “I” do, not an official policy. It sounded like the original poster had a bit of bad luck, and rather than lose all of the performance gains of a carbon front end, I wanted to suggest what I do as someone who is equally paranoid of stem/handlebar/fork failure. I do appreciate your feedback as well, and you are correct about the “if installed correctly and not damaged” part. I just don’t feel you can tell if a carbon component is damaged by looking at it. I guess I should really say NOT damaged, sometimes it is obvious it IS damaged.
but i can tell you this, in airplane construction, the loads are just as ‘uncontrolled’ (as you say) as in the real earth-bound world. fly enough and experience enough kicked-in-the-gut turbulence and hard landings, and you’ll probably concluded the loads are a lot more uncontrolled than in the bike world …
I am most definitely not looking for any handouts from Zipp. My body hurts quite a bit, but I don’t think it would be worth a Sub Zero or anything.
Funny, you say one thing, but then go on to hint otherwise. Your follow ups also sound like you really are looking for a replacement, and the problem with that is once 1 thing gets replaced usually the ‘seeker’ looks to get everything else replaced too.
As far as the accident, glad to hear you’re not seriously injured. I ride the Contours as well, they’ll probably get replaced once zipp releases their new bar which is supposed to be a cross between the Contour and SLC2.
Not only have you proven yourself a bad judge of character, but I am worried about your ability to read. Re-read my posts. I am not looking for anything from Zipp. Wrecks happen. I already have a replacement set of handlebars(not from Zipp…I purchased a new set of different handlebars.) on their way. I just want to get my bike back up and running as quickly as possible so I can ride.
Gained a whopping 80g in weight, some stiffness and a whole lot of piece of mind…