Mechanical effects of off-axis insertion of locking screws: should we do it?

Metallosis after using distal fibular locking plate for lateral malleolar fractures: a retrospective study

INTRODUCTION

Studies regarding the development of metallosis following open reduction and internal fixation (ORIF) of fractures are rarely found in orthopedic literature. The aim of the current study was to assess metallosis following ORIF using distal fibular locking plates to treat distal fibular fractures.

MATERIALS AND METHODS

69 patients who underwent surgery using locking compression plates to treat lateral malleolar fractures, with a minimum 1-year follow-up period and subsequent hardware removal were enrolled in our study. We divided the patients into 2 groups, to compare the complications and demographics: 38 patients, treated with ZPLP plate; 31 patients, treated with other plates.

RESULTS

During 1 year of postoperative follow-up, 20 complications developed: 6 superficial infections at the operative site, 1 case of nonunion, 3 cases of osteitis, 4 cases of hypaesthesia, 2 cases of peripheral neuropathy, and 4 cases of metallosis. No statistical difference was found in the rate of complications when comparing the treatment groups (Mann-Whitney U test, p < .05) except for metallosis. All 4 patients who developed metallosis were treated using a ZPLP plate, and metallosis did not develop at all in patients who underwent surgery using other plates.

CONCLUSION

In our study, metallosis developed more than was previously known, particularly after using LCPs to treat lateral malleolar fractures. Our findings and those in recent publications support the possibility that metallosis can occur not only in patients with arthroplasties, but also in patients with open reduction and internal fixation with LCPs. Surgeons should be aware of such risk of metallosis and be careful to select proper plates for internal fixation.

What Is the Cost of Off-Axis Insertion of Locking Screws? A Biomechanical Comparison of a 3.5 mm Fixed-Angle and 3.5 mm Variable-Angle Stainless Steel Locking Plate Systems

OBJECTIVE

 The aim of this study was to evaluate the effect of screw insertion angle and insertion torque on the mechanical properties of a 3.5 fixed-angle locking plate locking compression plate (LCP) and 3.5 variable-angle locking plate polyaxial locking system (PLS).

METHODS

 In the LCP group, screws were placed abaxially at 0, 5 and 10 degrees. In the PLS group, screws were placed at 0, 5, 10, 15 and 20 degrees abaxially. The insertion torque was set to 1.5 and 2.5 Nm in the LCP and PLS groups respectively. A load was applied parallel to the screw axis, and the screw push-out force was measured until the locking mechanism was loosened.

RESULTS

 The 3.5 LCP showed higher push-out strength than the 3.5 PLS when the screws were placed at 0 degree regardless of the insertion torque. The off-axis insertion of 3.5 LCP locking screws resulted in a significant decrease in push-out strength (p < 0.05). A higher insertion torque value significantly increased the screw holding strength for the 3.5 LCP (p < 0.05). The 3.5 PLS system had a significantly higher push-out force when the screws are at 0 degree than at 5, 10 and 15 degrees, and 20 degrees (p < 0.05) at any given insertion torque. An increase in the insertion torque did not have a significant effect on the push-out strength of the 3.5 PLS locking system.

CONCLUSION

 The 3.5 PLS is more sensitive to the screw insertion angle than to the insertion torque, whereas the 3.5 LCP is affected by both factors. Placing 3.5 LCP locking screws off-axis significantly reduces the screw holding strength; therefore, this approach has to be avoided. The findings of our research indicate that a 1.5 Nm torque can be used for a 3.5 PLS.

Biomechanical Analysis of the Proximal Femoral Locking Compression Plate: Do Quality of Reduction and Screw Orientation Influence Construct Stability?

OBJECTIVES

To investigate biomechanically in a human cadaveric model the failure modes of the proximal femoral locking compression plate and explore the underlying mechanism.

METHODS

Twenty-four fresh-frozen paired human cadaveric femora with simulated unstable intertrochanteric fractures (AO/OTA 31-A3.3) were assigned to 4 groups with 6 specimens each for plating with proximal femoral locking compression plate. The groups differed in the quality of fracture reduction and plating fashion of the first and second proximal screws as follows: (1) anatomic reduction with on-axis screw placement; (2) anatomic reduction with off-axis screw placement; (3) malreduction with on-axis screw placement; (4) malreduction with off-axis screw placement. The specimens were tested until failure using a protocol with combined axial and torsional loading. Mechanical failure was defined as abrupt change in machine load-displacement data. Clinical failure was defined as 5 degrees varus tilting of the femoral head as captured with optical motion tracking.

RESULTS

Initial axial stiffness (in N/mm) in groups 1 to 4 was 213.6 ± 65.0, 209.5 ± 134.0, 128.3 ± 16.6, and 106.3 ± 47.4, respectively. Numbers of cycles to clinical and mechanical failure were 16,642 ± 10,468 and 8695 ± 1462 in group 1, 14,076 ± 3032 and 7449 ± 5663 in group 2, 8800 ± 8584 and 4497 ± 2336 in group 3, and 9709 ± 3894 and 5279 ± 4119 in group 4. Significantly higher stiffness and numbers of cycles to both clinical and mechanical failure were detected in group 1 in comparison with group 3, P ≤ 0.044.

CONCLUSIONS

Generally, malreduction led to significantly earlier construct failure. The observed failures were cut-out of the proximal screws in the femoral head, followed by either screw bending, screw loosening, or screw fracture. Proper placement of the proximal screws in anatomically reduced fractures led to significantly higher construct stability. Our data also indicate that once the screws are placed off-axis (>5 degrees), the benefit of an anatomic reduction is lost.

Not All Polyaxial Locking Screw Technologies Are Created Equal: A Systematic Review of the Literature

BACKGROUND

Locking plate fixation strength relies on axial alignment of the screw axis and plate hole, with small deviations in alignment substantially decreasing the load to failure. In an effort to overcome this technical deficiency, polyaxial locking plates were designed to provide increased flexibility of screw positioning with the intent of not sacrificing fixation strength. The purpose of this article is to review the variety of polyaxial locking mechanisms currently available, to compare the biomechanical performance of these designs, and to highlight their differences, which may have clinical implications.

METHODS

A systematic review using the search terms "polyaxial locking," "variable angle locking," "polyaxial screws," and "variable angle screws" was conducted to identify all English-language articles assessing variable-angle locking screw technology. All articles directly comparing the biomechanical performance of polyaxial locking technologies were included.

RESULTS

Polyaxial locking is achieved by 5 described mechanisms: point-loading thread-in, cut-in, locking cap, expansion bushing, and screw-head expansion. With increasing insertion angulation, point-loading thread-in and cut-in designs demonstrate reduced failure strength. However, locking-cap fixation maintains consistent failure strength with increasing off-axis insertion angles.

CONCLUSIONS

Reports comparing polyaxial locking technologies are limited. The current biomechanical literature raises concerns that these mechanisms have various strengths and performance characteristics. Based on the results of the few studies that exist, it appears that locking-cap fixation provides superior biomechanical strength when compared with point-loading and cut-in designs. Additional studies are needed to assess variable-angle locking mechanisms more completely.

Locking Cap Designs Improve Fatigue Properties of Polyaxial Screws in Upper Extremity Applications

OBJECTIVES

This study sought to examine fatigue characteristics of 2 polyaxial locking screw designs: locking cap (LC) and cross-threaded (CT). The goal was to compare LC and CT implants at 0, 10, and 15 degrees of angulation to determine the effect of locking mechanism on screw-plate interface failure. The hypothesis was that LC implants would have superior fatigue properties in comparison to CT designs and that increased angulation of the screw would have a negative impact on the fatigue life of CT implants, but would not have any effect on LC implants.

METHODS

A total of 72 screws were tested in 4 upper extremity implants. Implants were subjected to cyclic shear loads and subsequent ramp to failure. Performance characteristics were statistically compared using nonparametric statistical methods.

RESULTS

Fatigue testing demonstrated that LC designs were consistently able to sustain a significantly higher number of cyclic loads than CT designs. There were no significant differences in the number of cycles sustained by LC designs because of changes in screw angle, but CT implants exhibited decreases in screw stability with increasing angulation.

CONCLUSIONS

Likely because of the spherical screw head geometry, LC fatigue characteristics are not influenced by the orientation of the screw relative to the plate. Application of an LC in the operating room requires additional time, but provides significantly more robust fixation of the screw, especially at oblique angles to the plate and provides a more predictable and consistent biomechanical result.

The biomechanical cost of variable angle locking screws

INTRODUCTION

Variable angle (VA) locking plates in fracture fixation surgery allow screws to be fastened to the plate within a conical "locus of vectors" in order to avoid existing prostheses, joint surfaces, or poor quality bone. Clinical failures of VA constructs in which screws have rotated at the plate/screw interface have been reported raising the concern that there may be a biomechanical cost for the increased flexibility that VA provides. The objective of this study was to test the mechanical properties of one commonly used VA locking mechanism with screws placed in both nominal and off-axis trajectories and compare these against the standard locking mechanism.

METHODS

VA locking screws were inserted into plates for distal femur fractures (VA Curved Condylar) at various angles (0° to 15° away from perpendicular). A control group of standard locking screws/plates was also tested. Maximum moment at the screw/plate interface and moment at two reference displacements were determined.

RESULTS

VA screws locked perpendicular to the plate provided the greatest maximum moment and moment at the reference displacements when using the VA system, and demonstrated lower moments compared to standard locking screws/plates (p<0.001). Based on linear regression, there was an average decrease of approximately 0.4 Nm screw-plate interface strength for every 1° increase in screw-plate angle (p<0.001). Decreases (p<0.05) were discovered in both maximum moment and moment at the reference displacements for screws locked at 5° relative to those locked at 0°, 10° relative to 0°, and 15° relative to 10°.

DISCUSSION

Standard locking systems provided greater resistance to rotational failure at the screw/plate interface than variable angle locking systems. Variable angle systems provided the greatest resistance to rotation when the screw was inserted perpendicular to the plate. As the off-axis angle increased, the resistance to rotation at the screw/plate interface decreased almost linearly. It is unknown if these differences are clinically significant in an actual fracture construct, but recent reported failures in the distal femur suggest that they might be.

CONCLUSION

Surgeons should weigh the risks and benefits of VA systems and attempt to minimize the off-axis angle magnitude when VA systems are selected.

Head-locking durability of fixed and variable angle locking screws under repetitive loading

Polyaxial locking screws are increasingly applied in fracture fixation. To investigate the durability of the head-locking mechanism, the removal torque of variable angle (VA) and fixed angle (FA) stainless steel and titanium locking screws was investigated without and after a cyclic loading test. Stainless steel (St) and titanium (Ti) 2.4 mm orthogonally inserted FA screws and 2.4 mm VA screws inserted in different inclinations (0°-15°) (n = 6 per group) were locked at 0.8 Nm. Removal torque was determined without (W) and after (A) cyclic loading (sinusoidal load, 5 Hz, constant amplitude of 25 N, up to 10'000 cycles, or failure). Significant differences in-between the groups were detected by Student's t-test (p < 0.05). Except VA Ti in 0deg and FA, all groups exhibited a drop in removal torque below the insertion torque without and after cyclic testing. The removal torque was (St: FA W:0.81 Nm ± 0.04 A:0.72Nm ± 0.04; VA0deg W:0.73 Nm ± 0.04 A:0.65 Nm ± 0.05; VA15deg W:0.51 Nm ± 0.05 A:0.50 Nm ± 0.08; Ti: FA W:0.82 Nm ± 0.03 A:0.70 Nm ± 0.04; VA0deg W:0.80 Nm ± 0.02 A:0.72 Nm ± 0.05; VA15deg W:0.55 Nm ± 0.03 A:0.54 Nm ± 0.06). In all groups, the removal torque after cyclic testing did not drop below 16% of the removal torque without cyclic testing. No head loosening was observed after cyclic testing. Stainless steel and titanium 2.4 mm fixed and variable angle locking screws provide a stable and lasting head-locking mechanism. © 2015 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 34:949-952, 2016.

What is the underlying mechanism for the failure mode observed in the proximal femoral locking compression plate? A biomechanical study

PURPOSE

Recently, several cases of clinical failure have been reported for the Proximal Femoral Locking Compression Plate (PF-LCP). The current study was designed to explore biomechanically the underlying mechanism and to determine whether the observed failure was due to technical error on insertion or to implant design.

METHODS

A foam block model simulating an unstable intertrochanteric fracture was created for 3 study groups with 6 specimens each. Group C was correctly instrumented according to the manufacturer's guidelines. In Group P and Group A, the first or second proximal screw was placed with a posterior or anterior off-axis orientation by 2° measured in the transversal plane, respectively. Each construct was cyclically tested until failure using a test setup and protocol simulating complex axial and torsional loading. Radiographs were taken prior to and after the tests. Force, number of cycles to failure and failure mode were compared.

RESULTS

A screw deviation of 2° from the nominal axis led to significantly earlier construct failure in Group P and Group A in comparison to Group C. The failure mode was characterised by loosening of the off-axis screw due to disengagement with the plate, resulting in loss of construct stiffness and varus collapse of the fracture.

CONCLUSIONS

In our biomechanical test setup, the clinical failure modes observed with the PF-LCP were reproducible. A screw deviation of 2° from the nominal axis consistently led to the failure. This highlights how crucial is the accurate placement of locking screws in the proximal femur.