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Fabrics and waterproofing

Seam tape

Also called taped seams, seam sealing

What is seam tape?

Seam tape is a waterproof strip heat-bonded over the stitch line inside a garment or tent. Every needle hole is a hole in the waterproofing, so a shell with an untaped seam leaks there regardless of how good the fabric is.

Seam tape at a glance

Fully taped
Every seam
Critically taped
Shoulders and hood only
Fails by
Lifting at the edges with age

Why seams need taping at all

Sewing two pieces of waterproof fabric together punches a line of holes through both. The fabric can be rated to 20,000 mm and it makes no difference at the seam. Seam tape is the strip bonded over that line on the inside to close the holes, and it's applied with heat and pressure rather than glue.

Fully taped against critically taped

Brands describe coverage two ways. Fully taped means every seam; critically taped means only the ones judged most exposed, usually shoulders and hood. Critically taped is cheaper and lighter and it's a genuine compromise, so it's worth knowing which one you're buying before it rains sideways.

Why tape is what ages first

Tape is also the part that ages worst. Look inside an old shell and you'll often find the tape lifting at the edges, curling, or peeling away in strips. Once that starts the garment leaks at the seam and the repair is fiddly. Gear repair tapes and seam sealants can buy time, but a shell with tape failing in several places has reached the end.

What this means when you're choosing

  • Fully taped rather than critically taped if you hike in real weather
  • Tape edges inside a used jacket, which is where failure starts
  • Narrow tape on lightweight shells, which saves weight and is more delicate

The common mistake

Assuming a waterproof rating covers the seams

Every stitch is a hole. A 20,000 mm fabric with an untaped seam leaks at that seam and the rating tells you nothing about it. On silicone-coated shelters tape will not bond at all, so those ship unsealed and you do it yourself.

Common questions

What's the difference between fully taped and critically taped?

Fully taped seals every seam. Critically taped seals only the most exposed ones, leaving the rest to leak slowly in sustained rain. For a jacket you'll rely on in bad weather, fully taped is worth the extra.

Can lifting seam tape be repaired?

Sometimes. A warm iron through a cloth can re-bond tape that's just starting to lift, and a liquid seam sealant works on small sections. Widespread peeling isn't practically fixable.

Where this comes up

Guides on Tom's Hiking where seam tape changes which product is right for you.

More in fabrics and waterproofing

DWR

DWR is a chemical finish applied to the outside of a rain shell so water beads up and rolls off instead of soaking into the face fabric. It wears off with use and washing, and reviving it is routine maintenance rather than a repair.

Waterproof-breathable membrane

A waterproof-breathable membrane is a thin film bonded inside a shell fabric with pores small enough to block liquid water but large enough to pass water vapour. It's what makes a rain jacket different from a plastic poncho.

Gore-Tex

Gore-Tex is a brand of waterproof-breathable membrane made by W. L. Gore & Associates, and the name most people know the technology by. Gore licenses it to clothing makers under strict construction rules rather than selling finished garments.

ePTFE

ePTFE is expanded polytetrafluoroethylene, the microporous film at the heart of the original Gore-Tex and several competing membranes. Stretching PTFE creates billions of pores per square inch that block liquid water and pass vapour.

Hydrostatic head

Hydrostatic head measures how much water pressure a fabric holds before it leaks, expressed as a column height in millimetres. A 20,000 mm rating means a 20-meter column of water sat on the fabric before the first drops came through.

MVTR

MVTR measures how much water vapour passes through a fabric in a day, given in grams per square meter per 24 hours. Higher numbers mean a more breathable fabric, with most hiking shells landing between 10,000 and 25,000.

RET

RET measures how much a fabric resists the evaporation of sweat, tested under ISO 11092. It runs the opposite way to most ratings: lower is better, with under 6 counting as extremely breathable and over 20 as barely breathable at all.

Wetting out

Wetting out is when a shell's outer fabric absorbs water instead of shedding it, because the DWR finish has worn off. The membrane still blocks rain, but breathability collapses and the jacket feels like it's leaking from the inside.

2L, 2.5L and 3L laminates

These describe how many layers are bonded together in a shell. 2L has a loose liner hanging inside, 2.5L prints a protective pattern straight onto the membrane, and 3L bonds a fabric backer to it. Durability and next-to-skin feel go up with each step.

Denier

Denier is the weight in grams of 9,000 meters of a yarn, written as a number followed by D. It describes how thick the individual threads are, so higher denier usually means a heavier, tougher fabric, though weave and material matter too.

Dyneema Composite Fabric

Dyneema Composite Fabric is a non-woven laminate of UHMWPE fibers sandwiched between polyester films. It is waterproof from the moment it is made, does not stretch or sag when wet, and is the lightest shelter material in common use, at several times the price.

Ripstop

Ripstop is a weave with thicker reinforcing threads laid in at regular intervals, forming the faint grid you can see on tent and pack fabric. The grid does not stop a tear starting, it stops one that has started from running across the whole panel.

Silnylon

Silnylon is ripstop nylon impregnated with silicone on both faces, the standard fabric for lightweight tents and tarps. It is strong and cheap for its weight, and it stretches when wet, which is why a silnylon shelter sags overnight and needs retensioning.

PU coating

A PU coating is a polyurethane layer applied to the inside of a tent, pack or stuff sack fabric to make it waterproof. It is cheap, takes seam tape well and is what most budget shelters use, and it breaks down with age in a way silicone does not.

Cordura

Cordura is a brand of high-tenacity nylon fabric known for abrasion resistance, used where a pack meets rock and grit. It is a specification a mill licenses rather than a single fabric, so Cordura appears in weights from light shelter cloth to heavy pack bottoms.

Softshell

A softshell is a stretchy woven fabric with a brushed or knitted backing that blocks wind and sheds light rain while still breathing hard. It replaces a rain shell on cold, dry, windy days and is the standard fabric for technical hiking pants.

Base layer

A base layer is the garment worn directly against your skin under everything else. Its job is moving sweat off your skin so it evaporates somewhere other than on you, which is why warmth is a secondary consideration and cotton is disqualified.

Merino wool

Merino wool is fine-diameter wool from Merino sheep, spun for next-to-skin clothing at roughly 17 to 19.5 microns. That fineness is what stops it prickling, and it brings odour resistance and warmth when damp at the cost of abrasion life.

Fabric weight (gsm)

Fabric weight in gsm is the mass of one square meter of the cloth, in grams. On a base layer it is the single number that sets the temperature window: about 150 gsm for warm weather, about 200 gsm for three-season hiking, 280 and up for cold.

UPF

UPF, or Ultraviolet Protection Factor, rates how much ultraviolet radiation a fabric blocks. A UPF 30 garment lets about one thirtieth of the UV hitting it through, so it blocks roughly 96.7 percent; UPF 50 lets one fiftieth through, or 98 percent.

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