In reply to Mick Ryan - UKClimbing.com:
I used to work for Lyon Equipment testing gear for an HSE research contract. I still work in Rope Access and have been teaching gear inspection for 6 years or so now...
Some good info here but still some points worth adding. Lyon's current course is a full week so I'll try to stick to just nylon webbing/ belay loops!!:
Firstly, strength.
Yes, belay loops are massively strong, typically in excess of 30 KN (3 tons) - probably stronger than any other piece of gear you own or the anchor.
Secondly, obsolescence.
Stored correctly, Nylon doesn't lose strength over 10 years or so. UV light will weaken it, as will any use which inevitably cause wear and tear which will weaken it.
Hence manufacturers usually recommend a lifespan of between three and ten years for all-fabric products. This is lifetime 'in-use' and is in addition to correct storage by shops, distributors etc.
However this is ALWAYS with the proviso that lifetime can be as short as a single use.
Thirdly, wear.
Webbing is very susceptible to damage by abrasion. On courses we do a simple demo with 3 quickdraws:
One gets a crampon point stabbed through it, one gets cut a quarter of the way through and the third gets a five second rub over a half-inch long section from the striking sandpaper on the side of a box of matches.
When broken, the first loses little strength, the second is weakened by pretty much the same amount as you have cut through (ie a quarter in this case), the last has usually lost at least half of its strength, despite looking much less serious than the others originally.
This is due to the fact that all the fibres making up webbing are exposed to the surface at some point over only an inch or so - the same reason that webbing is far more susceptible to UV damage than rope which keeps 70% or so of the strength hidden in the core.
NB.'Fluffing' due to age is not the same as abrasion damage and there is some evidence to suggest it helps protect webbing. If you look (very!) closely fluffing due to age consists of pulled loops whereas abrasion wear cuts the individual fibres and you see the fibre ends.
So why was he still using it?
It can be very difficult to decide when a harness is knackered.
Wear is usually a very gradual process, building up slowly over years, and is especially difficult to notice on your own gear as you never see a significant change. Hence why in rope access gear has to have a 6 monthly inspection, usually done by an independent person.
Smaller sections of localised wear are fairly easy to assess, but it is extremely difficult to say at what point general wear becomes a threat - hence why manufacturers suggest lifetimes. Having said that, I think it is the localised wear that we need to worry about, not general 'age'.
Finally, how did such serious wear occur on a belay loop?
From a UK perspective I agree it can be hard to see how a belay loop could get such damage. However in Yosemite routes are longer and wide cracks are very common. I could easily see how thrutching up just one off-width could cause more damage than five seconds with a matchbox.
US climbers also commonly larks-foot a sling or daisy chain into their belay loop for quick clipping into belays. Over a lot of use this could also cause some serious local abrasion - made worse by the fact the damage would be hidden by the larks-foot itself.
Another danger is using worn karabiners. Steel bolt hangers will easily damage aly biners. This isn't significant for the strength of the biner but it can create tiny sharp edges that can damage slings and ropes. Hence why quickdraws should always be used with dedicated 'ends'. I could see how routinely swapping a belay device from harness to anchor bolt, as you often do with magic plate type devices, could cause a similar problem.
Some of these last factors might sound scary, but as long as you are aware of them its very easy to eliminate them. You never liked off widths anyway did you? It is worth, though, doing a regular careful inspection paying special attention to abrasion.
As mentioned higher up the thread, this is a very rare occurrence (I can't recall any others) which is reassuring. This is partly due to the huge safety factors built into new gear, but also that generally folk are pretty conscientious when their life is on the line.