Composite Strapping Width and Strength Guide: How to Size your System for any Load

Choosing the wrong strapping size can quickly lead to serious problems across your supply chain.

Undersized strapping may snap under tension, allowing loads to shift, collapse, or become unstable during transit. This not only risks damaging the product but also poses safety hazards for workers and transport operators.

In many cases, incorrect strapping selection can also result in non-compliance with Australian load restraint regulations, exposing your business to penalties and liability.

That’s why understanding composite strapping sizes matters. Whether you’re securing palletised freight for road transport, export cargo in containers, or irregular loads for longer-haul movement, choosing the right strength, flexibility, and width is key to performance.

This guide is designed as a practical composite strap width guide for warehouses, exporters, and logistics teams. If you’ve been asking, “What size composite strap do I need?” the answer depends on load weight, stability, transport mode, and the conditions the load is likely to face from dispatch through to delivery.

Click the section to read:

• What Is Composite Strapping and Why Use It?
• Types of Strapping
• Understanding Composite Strapping Width vs Strength
• What is Composite Polyester Strapping
  ⦿ FAQ: What is the difference between woven and composite strapping?
  ⦿ FAQ: How long does composite strapping last?
• Overview of Polyester Strapping (PET)
• How to Use Polyester Strapping
  ⦿ FAQ: What is the Difference Between Polyester and Polypropylene Strapping?
  ⦿ Dangers of Polyester Strapping
• Overview of Steel Strapping
  ⦿ FAQ: What is the Alternative to Steel Strapping?
  ⦿ Dangers of Steel Strapping
• Overview of Polypropylene Strapping
  ⦿ FAQ: Is Polypropylene Strapping recyclable?
  ⦿ How to Keep Polypropylene Straps from Fraying
• Choosing the Right Type of Composite Strapping
• Strapping Seals Compatibility Table
• Benefits of Fibre Composite Strapping

What Is Composite Strapping and Why Use It?

Strapping is used to secure loads during storage and transport. In simple terms, it means securing goods with a strong strap to keep them together. When implemented correctly, strapping plays a key role in reducing damage, improving handling safety, and ensuring loads arrive intact.

In Australia, proper strapping is closely tied to Chain of Responsibility (CoR) obligations and load restraint compliance. If a load moves or fails in transit, it’s not just a product issue; it’s a safety and legal risk.

That’s why selecting the right strapping system is essential.

You’ll commonly see strapping used across pallets, shipping containers, flat racks, and heavy machinery. Common strapping materials include composite strapping, polyester (PET) strapping, steel strapping and polypropylene strapping. Each has different characteristics suited to different load types and transport conditions.

Types of Strapping

There’s no single strapping solution that works for every load. The right choice depends on the products requiring securement, the load profile including weight, how it behaves in transit, and how it’s handled across the supply chain.

In most warehouse and transport environments, strapping needs to do three things well: hold tension, manage movement, and remain safe to apply and remove. Different materials achieve this in different ways.

The main strapping types used in Australia are:

• Composite strapping
• Polyester strapping (PET)
• Steel strapping
• Polypropylene strapping (PP)

Each material has its own strengths and limitations. For example, X-Pak composite strapping is known for its flexibility and shock absorption, while steel provides maximum strength for extreme loads. Understanding these differences is key to selecting the right system for your application.

Quick Comparison of Strapping Types

Understanding Composite Strapping Width vs Strength

When choosing among composite strapping sizes, width is one of the first things to consider. As a general rule, wider strap sizes tend to offer higher breaking strain, which means they are typically used for heavier or more demanding applications.

As a general guide:

• 16 mm straps work well for medium loads
• 19 mm straps are designed for heavy, bulky, fragile or export cargo
• 25 mm straps are designed for extremely heavy-duty loads

That said, width alone does not determine performance. The strap material, construction, buckle compatibility, and the nature of the load all play a role in how the system performs.

It is also important to distinguish between breaking strain and working load. Breaking strain refers to the point at which the strap may fail under test conditions. Working load refers to the safer operating level used in real-world applications.

Load type also plays a critical role. Rigid loads (like bricks or steel) behave differently from shifting loads (like timber or palletised goods), which require more flexibility and shock absorption.

Quick Composite Strapping Width vs Strength Table

Note: This table is a general guide only. Strap selection should always be based on the load, transport conditions, and the full restraint system.

What is Composite Polyester Strapping

Composite polyester strapping, also known as poly composite strapping, is a high-performance load restraint solution for demanding transport and industrial applications. It’s made from high-tenacity polyester yarns arranged in parallel for maximum strength, and then coated with a protective polymer layer. This construction creates a strap that delivers both durability and flexibility, something traditional materials often struggle to balance.

Key Benefits of Composite Polyester Strapping

• High strength with flexibility: Delivers strong load restraint while adapting to movement without losing tension.
• Shock absorption (ideal for transport): Absorbs impact and vibration during transit, reducing load shift.
• Safer than steel (no recoil risk): Eliminates dangerous snap-back, improving on-site safety for operators.
• Weather and UV resistance: Performs reliably in outdoor and export conditions, resisting moisture, heat, and sunlight.

Supporting Components

• Composite strapping buckles: Provide secure, non-slip fastening for consistent tension
• Composite strapping tools: Enable safe and effective tensioning, cutting, and application
• Composite strapping dispensers: Improve handling efficiency and keep the strap organised on-site

Common Use Cases of Composite Polyester Strapping

• Timber packs: Securing uneven, heavy bundles
• Export cargo: Reliable for long-distance shipping and container transport
• Machinery: Stabilising heavy and high-value equipment
• Irregular loads: Ideal for loads that shift, settle, or have uneven shapes

FAQ: What is the difference between woven and composite strapping?

Woven and composite strapping are both fibre-based polyester strapping products, but they are built differently and behave differently in use.

Woven strapping is made from interlaced polyester fibres. This gives it a softer, more flexible feel, which can make it easier to handle and better suited to applications where the strap needs to conform more readily around the load.

Composite strapping is made from parallel polyester yarns that are bonded and coated. As a result, it tends to have a firmer structure and better abrasion resistance than woven strapping, while remaining flexible enough for transport use.

FAQ: How long does composite strapping last?

Composite strapping has an excellent shelf life and can last for several years when stored correctly in a dry, shaded environment.

Its polymer coating helps protect the internal polyester fibres from moisture, UV exposure, and general wear. This durability makes it highly reliable for long-haul transport and export applications, where loads may be exposed to varying weather conditions.

Unlike some materials, it does not easily degrade or lose tension, ensuring consistent performance from storage through to final delivery.

Overview of Polyester Strapping (PET)

Polyester strapping (commonly referred to as PET strapping) is a high-strength plastic strapping material widely used across industrial and logistics applications. Designed to handle heavy, rigid loads, it is commonly used for products such as bricks, steel bundles, palletised goods, and construction materials, where maintaining consistent tension is critical.

In many operations, PET strapping is used as an alternative to steel because it offers strong performance, easier handling, and a lower risk profile. It is lighter, easy to manage on-site, and well-suited to environments where efficiency and consistency matter.

Key Benefits of Polyester Strapping (PET)

• High tensile strength: Suitable for securing heavy, rigid loads like steel, bricks, and palletised goods
• Retains tension over time: Maintains load stability even when products shift or settle during transport
• Machine-friendly: Compatible with automated strapping machines and tools for efficient, high-volume operations

How to Use Polyester Strapping

Using polyester strapping involves three key steps:

1. Tension
2. Seal
3. Cut

First, the strap is placed around the load and tensioned to the required level to secure it firmly. Next, a seal or friction weld is applied to lock the strap in place. Finally, the excess strap is cut cleanly. This process can be carried out using manual, battery-operated, or pneumatic tools, depending on the volume and application.

FAQ: What is the Difference Between Polyester and Polypropylene Strapping?

Polyester (PET) and polypropylene (PP) strapping are both plastic strapping materials, but they are designed for different applications.

PET strapping is stronger and has lower stretch, making it ideal for heavy-duty loads such as pallets, bricks, and steel. It maintains tension well over time, especially during transport.

In contrast, PP strapping is lighter and more elastic. It stretches more under tension, which makes it easier to apply but less effective at maintaining load stability over time. For that reason, it is typically used for lighter applications such as cartons, bundling, and short-term load restraint.

Polyester Strapping Breaking Strain Range

Polyester (PET) strapping offers a medium-to-high breaking strain, making it suitable for securing a wide variety of loads. Depending on the width and thickness, it can handle anything from moderate pallet loads to heavy-duty applications. Its strength and tension retention make it particularly effective for palletised goods, where maintaining stability during transport and storage is essential.

Other Types of Polyester Strapping

• Embossed PET: Features a textured surface that improves grip and reduces slippage, ideal for high tension in hand battery tools, as well as a faster melt process.
• Smooth PET: Has a flat finish that allows for higher tensioning, is best suited for machine use, heavy-duty applications, and has slightly higher break strain.
• Jumbo Rolls: Larger roll sizes designed for high-volume operations, reducing changeovers and improving efficiency in automated environments.

Read more: Top Benefits of PET Strapping for Australian Businesses

Overview of Steel Strapping

Steel strapping is a heavy-duty load restraint solution used in applications where very high strength and minimal elongation are required. It has been used across industrial and transport environments for decades, particularly for securing steel coils, heavy machinery, construction materials and other high-mass loads.

One of the defining characteristics of steel strapping is its rigidity. It holds tensions with very little stretch. This makes it ideal for loads that need to remain tightly secured with minimal movement during transport.

Steel performs well in demanding conditions, including applications involving sharp edges or higher temperatures, where some plastic-based strapping products may not be suitable.

However, steel strapping requires specialised tools and trained handling due to its rigidity and potential safety risks. While it remains a traditional choice for very heavy-duty applications, many industries are now exploring alternatives, such as composite or PET strapping, for improved safety and ease of use without significantly compromising strength.

FAQ: What is the Alternative to Steel Strapping?

A common alternative to steel strapping is PET or composite strapping, which offers safer and more flexible solutions without sacrificing strength. They are significantly lighter, easier to handle, and eliminate the risks associated with sharp edges and recoil. This makes it ideal for many heavy-duty applications where safety and efficiency are a priority.

Dangers of Steel Strapping

• High injury risk: Steel strapping has sharp edges that can easily cause cuts and lacerations during handling
• Snap-back hazard: When cut under tension, steel straps can recoil violently, posing serious safety risks to operators nearby
• Heavy and difficult to handle: Its rigid nature increases strain during application and removal
• Requires trained handling: Proper training and specialised tools are essential to minimise risks and ensure safe use

Steel Strapping Breaking Strain Range

Steel strapping offers the highest breaking strain range of all strapping materials, making it suitable for the most demanding applications. It is designed to secure extremely heavy and rigid loads where minimal stretch is required. This high strength makes it ideal for industries handling steel products, machinery, and other large-scale industrial goods.

Read more: Steel vs PET Strapping: Key Differences and When to Use Each

Overview of Polypropylene Strapping

Polypropylene (PP) strapping is a lightweight, low-cost strapping material commonly used for light-duty packing and internal handling applications. It is typically used to secure cartons, bundle products, and stabilise lighter pallet loads where high restraint is not required.

PP strapping is flexible and stretches under tension. This makes it ideal for applications where loads are not overly heavy or rigid. It is also easy to handle and can be applied using manual tools or automated strapping machines, depending on operational needs.

While it does not offer the same strength as polyester or steel strapping, polypropylene remains a practical choice for businesses seeking a reliable, budget-friendly solution for everyday packaging and light-load restraint requirements.

FAQ: Is Polypropylene Strapping recyclable?

Yes, polypropylene (PP) strapping is recyclable, provided it is clean and processed through appropriate recycling streams.

Many businesses incorporate PP strapping into their broader plastic recycling processes, particularly in warehouse and packaging environments where materials can be separated and managed more consistently.

Polypropylene Strapping Breaking Strain Range

Polypropylene strapping offers a lower breaking strain range, making it best suited for light-duty loads such as cartons, bundled products, and small palletised goods. It is best suited to light-duty applications such as cartons, bundled products, and smaller palletised goods, where high restraint force is not required.

How to Keep Polypropylene Straps from Fraying

Polypropylene strapping can fray or split if it is cut poorly or handled roughly, particularly in high-volume packaging environments.

To help reduce fraying:

• Heat sealing: Applying heat to the cut ends helps fuse the fibres, preventing fraying and maintaining strap integrity
• Use proper cutting tools: Clean, sharp cutters ensure a neat edge and reduce the risk of strands loosening over time
• Avoid rough handling: Minimising abrasion during use helps extend the life of the strap and prevent damage

Choosing the Right Strapping Solution

Selecting the right strapping solution is critical to ensuring load safety, transport efficiency, and compliance. Different materials perform better in different applications, so it’s important to carefully assess your requirements before making a decision.

Key decision factors include:

• Load weight: Heavier loads require higher tensile strength and wider strap options
• Transport method: Road, rail, or sea transport can impact how much movement and vibration a load will experience
• Load shape (rigid vs irregular): Irregular or shifting loads benefit from more flexible strapping solutions
• Environmental exposure: Outdoor storage, moisture, and UV exposure can affect strap performance
• Compliance requirements: Must align with Australian load restraint guidelines and safety standards

If you’re asking what size composite strap you need, the answer depends on how you balance these factors. This is where a clear composite strap width guide becomes valuable, helping match strap size to load demands without over- or under-specifying.

For many industries, composite strapping offers a reliable middle ground, delivering strength, flexibility, and safety without the risks associated with steel. However, every application is different. A site-specific assessment ensures you select the right system, tools, and configuration for optimal performance and compliance.

Strapping Seals Compatibility Table

Choosing the correct sealing system is just as important as selecting the right strap. The seal or buckle ensures the strap remains under tension throughout transport, directly affecting load stability, safety, and compliance. Using an incompatible seal can lead to slippage, loss of tension, or even load failure.

Common types of seals include:

• Lap Over Seals: Suitable for light to medium-duty applications, typically used with PET and PP strapping
• Semi-Open Seals: Allow faster application and are commonly used in higher-volume operations
• Serrated Strapping Seals: Provide a stronger grip and are ideal for heavy-duty PET and steel strapping
• Steel Strapping Buckles: Designed for use with steel strapping in high-tension applications
• Sheradised Lashing Buckle: Corrosion-resistant, used in lashing and composite systems
• Sheradised Strapping Buckles: Commonly paired with composite strapping for secure, non-slip performance

Strapping Seals Compatibility Table

Each seal type is designed to work with specific materials, so ensuring compatibility between the strap and seal is essential for optimal performance. The right combination improves tension retention, reduces risk, and ensures your load remains secure from dispatch to delivery.

Benefits of Fibre Composite Strapping

Fibre composite strapping is widely recognised as a reliable and versatile solution for modern load restraint applications. It combines strength, flexibility, and safety, making it suitable across a range of industries, from warehousing to export logistics.

Key advantages include:

• Safer handling: No sharp edges or dangerous snap-back, reducing risk to operators
• High strength-to-weight ratio: Delivers strong load containment without the bulk of steel
• No rust or corrosion: Performs consistently in humid, outdoor, and export conditions
• Re-tension capability: Can be re-tightened during transit if loads settle or shift
• Ideal for export loads: Absorbs shock and vibration, maintaining stability over long distances

At X-Pak Global, fibre composite strapping is backed by deep industry expertise and a commitment to quality. With a full range of tested products, tooling, and on-site support, we help ensure your strapping system is not only effective but also compliant with Australian load restraint requirements.

Choose X-Pak Composite Strapping Solutions in Australia

Choosing the correct composite strapping sizes is essential to ensure load safety, compliance, and performance during transport. At X-Pak Global, you get expert advice tailored to your application. From custom solutions to site visits and load testing, we help you select the right system, including a full range of tools and accessories.

Book a free site assessment with our team today.