Background Long-lasting insecticidal nets (LLINs) are expected to last for at least 3 years, but whilst this may be achieved from an insecticidal perspective, physical protection is frequently compromised much earlier because of the rapid accumulation of holes during use. To understand why LLINs are so susceptible to loss of physical integrity, thousands of hole damage sites in LLINs retrieved from the field in Africa and Asia were forensically studied to identify the persistent underlying causes. Methods A total of 525 LLINs consisting of six different brands from five different countries across Africa and Asia were collected from the field after 1 to 3 years in use. More than 42,000 individual sites of hole damage were analysed based on the morphology and size of each individual hole, aided by optical microscopy (OM) and scanning electron microscopy (SEM). The fracture morphology enabled positive identification of the underlying mechanisms of the damage. Results Across all LLINs and geographical settings, mechanical damage is the primary cause of holes and loss of physical integrity in LLINs (63.14% by frequency and 81.52% by area). Snagging is the single most frequent mechanical damage mechanism, whilst the largest sized holes in LLINs result from seam failure and tearing. Abrasion and hole enlargement are also responsible for a progressive loss in the physical integrity of nets. Collectively, these five modes of mechanical damage can be expected to result from normal use of LLINs by households. Evidence of deliberate cutting, burn holes and rodent damage was observed to a lesser degree, which LLINs are not designed to withstand. Conclusions Loss of physical integrity in LLINs is an inevitable consequence of using a vector control product that has an inherently low resistance to mechanical damage during normal use. To improve performance, new specifications based on laboratory textile testing is needed, to assess the resistance of LLIN products to the primary causes of mechanical damage when in use, which are snagging, tearing, abrasion and hole enlargement. Seam construction also needs to meet a revised minimum standard to reduce the risk of a rapid loss of physical integrity during use.

Background LLINs are susceptible to forming holes within a short time in use, compromising their ability to provide long-term physical protection against insect-borne vectors of disease. Mechanical damage is known to be responsible for the majority of holes, with most being the result of snagging, tearing, hole enlargement, abrasion and seam failure, which can readily occur during normal household use. To enable an assessment of the ability of LLINs to resist such damage prior to distribution, a new suite of testing methods was developed to reflect the main damage mechanisms encountered during normal use of LLINs. Methods Four existing BS EN and ISO standards used by the textile industry were adapted to determine the ability of LLINs to resist the most common mechanisms of real-world damage experienced in the field. The new suite comprised tests for snag strength (BS 15,598:2008), bursting strength (ISO 13938-2:1999), hole enlargement resistance (BS 3423–38:1998), abrasion resistance (ISO 12947-1:1998) and new guidance around the seam construction of LLINs. Fourteen different LLINs were tested using the new suite of tests to evaluate their resistance to damage. Results The resistance to mechanical damage of LLINs is not the same, even when the bursting strength values are comparable. Differences in performance between LLINs are directly related to the fabric design specifications, including the knitted structure and constituent yarns. The differences in performance do not primarily relate to what polymer type the LLIN is made from. LLINs made with a Marquisette knitted structure produced the highest snag strength and lowest hole enlargement values. By contrast, LLINs made with a traverse knitted structure exhibited low snag strength values when compared at the same mesh count. Conclusions Prequalification of LLINs should consider not only insecticidal performance, but also inherent resistance to mechanical damage. This is critical to ensuring LLINs are fit for purpose prior to distribution, and are capable of remaining in good physical condition for longer. The new suite of test methods enables the performance of LLINs to be assessed and specified in advance of distribution and can be used to establish minimum performance standards. Implementation of these testing methods is therefore recommended.