The Effect of Suture Caliber and Number of Core Strands on Repair of Acute Achilles Ruptures
Authors: Backus Jonathon D. , Marchetti Daniel C. , Slette Erik , Dahl Kimi D. , Turnbull Travis L. , Clanton Thomas O. 
Published: October 2016

Category: Sports Introduction/Purpose: Controversy exists in Achilles rupture management with options ranging from nonoperative care to open surgical repair. Current literature suggests re-rupture rates are lower with operative repair; therefore, surgery is recommended for active populations. The effect of suture caliber or number of core stands has not been studied in Achilles repair. Varying these factors may allow for a construct capable of earlier weight-bearing and rehabilitation. We hypothesized the number of core strands and suture caliber used in Achilles repair would significantly affect strength and gapping during a simulated early rehabilitation protocol. Methods: Sixteen cadaveric human foot and ankle specimens with no prior injuries or surgeries were utilized. Simulated midsubstance Achilles ruptures were created 6 cm proximal to the calcaneal insertion in 13 ankles. Specimens were randomly allocated to 1 of 4 groups: (1) intact Achilles tendon, (2) open repair using No. 2 suture with four core sutures and two 2mm suture-tape core sutures, (3) open repair using No. 2 suture with two core sutures and four 2mm suture-tape core sutures, and (4) open repair using No. 2-0 suture with 12 core sutures. Repairs consisted of three modified Kessler sutures and an epitenon stitch with a 3-0 monofilament suture. Specimens were subjected to a cyclic loading protocol simulating early, progressive postoperative rehabilitation: 250 cycles at 1 Hz for each loading range: 20-100, 20-200, 20-300, and 20-400 N. A 1-way ANOVA was used to test significance among repair groups. Results: During biomechanical testing, all repairs survived the first two loading stages. However, elongation trends during stage 1 (Figure 1) were consistent among subsequent cyclic loading stages. No significant elongation differences were observed between any of the repair groups (Groups 2-4), with mean displacements of 4.94 ± 0.90 mm, 3.93 ± 0.92 mm, and 5.35 ± 0.34 mm, respectively, at the end of the first loading stage. In Group 2, one repair failed during the fourth stage and 4 survived all four stages. In Group 3, one repair failed during the third stage and two repairs during the fourth stage. In Group 4, two repairs failed during the fourth stage and two survived all four stages. The average number of cycles to failure for Groups 2-4 was 967, 783, and 940 cycles, respectively. Conclusion: In this study, all but one repair survived 750 cycles. This was superior to a 6 core strand repair with No. 2 suture similarly evaluated in a previous study (427 cycles). When 4 of 6 strands were substituted with suture-tape, repair gapping decreased initially; yet, these repairs failed earlier. Gapping in Groups 2 and 4 was similar to the previously evaluated repair; however, the number of cycles to failure was higher. Therefore, substituting suture-tape for 2 core strands or doubling the core strands with a smaller caliber suture may be biomechanically superior and allow for earlier return to function.