Intraoperative techniques to reduce the potential of set-screw loosening in long spinal constructs: a static and fatigue biomechanical investigation

Development and biomechanical analysis of an axially controlled compression spinal rod for lumbar spondylolysis

BACKGROUND

To elucidate the differences in mechanical performance between a novel axially controlled compression spinal rod (ACCSR) for lumbar spondylolysis (LS) and the common spinal rod (CSR).

METHODS

A total of 36 ACCSRs and 36 CSRs from the same batch were used in this study, each with a diameter of 6.0 mm. Biomechanical tests were carried out on spinal rods for the ACCSR group and on pedicle screw-rod internal fixation systems for the CSR group. The spinal rod tests were conducted following the guidelines outlined in the American Society for Testing and Materials (ASTM) F 2193, while the pedicle screw-rod internal fixation system tests adhered to ASTM F 1798-97 standards.

RESULTS

The stiffness of ACCSR and CSR was 1559.15 ± 50.15 and 3788.86 ± 156.45 N/mm (P < .001). ACCSR's yield load was 1345.73 (1297.90-1359.97) N, whereas CSR's was 4046.83 (3805.8-4072.53) N (P = .002). ACCSR's load in the 2.5 millionth cycle of the fatigue four-point bending test was 320 N. The axial gripping capacity of ACCSR and CSR was 1632.53 ± 165.64 and 1273.62 ± 205.63 N (P = .004). ACCSR's torsional gripping capacity was 3.45 (3.23-3.47) Nm, while CSR's was 3.27 (3.07-3.59) Nm (P = .654). The stiffness of the pedicle screws of the ACCSR and CSR group was 783.83 (775.67-798.94) and 773.14 (758.70-783.62) N/mm (P = .085). The yield loads on the pedicle screws of the ACCSR and CSR group was 1345.73 (1297.90-1359.97) and 4046.83 (3805.8-4072.53) N (P = .099).

CONCLUSION

Although ACCSR exhibited lower yield load, stiffness, and fatigue resistance compared to CSR, it demonstrated significantly higher axial gripping capacity and met the stress requirement of the human isthmus. Consequently, ACCSR presents a promising alternative to CSR for LS remediation.

Use of the "Two-Three Click" Protocol in Screw Stabilization of a Patient With Loosened Nuts and Dislocation of Rods - A Case Report

Vertebral fixation, utilizing titanium screws, is a highly prevalent technique employed to address spinal instability. Screw stabilization malfunction due to pedicle screw nuts loosening is rare. Under tightening the internal nut in the pedicle screw head may increase the likelihood of rod movement within the system resulting in severe pain when moving. Our goal is to raise the attention of surgeons when tightening the screws nuts of the screw stabilization because the consequences for the patient can be subsequent additional operations and complications.  This report describes a clinical case of a 40-year-old man who underwent three surgeries at different clinics several years ago for disc herniation at the L4-L5 level and screw stabilization at the same level. The patient presents to the neurosurgery clinic of Saint Marina University Hospital with a clinical manifestation of low back pain escalating with movement, with a pain intensity rating of six on the Visual Analogue Scale (VAS). From the CT scan, it was revealed a malfunction in the screw stabilization with loosening of the screw nuts and dislodgement of the rods. Screw stabilization was restored using intraoperative X-ray guidance and following the "two-three click" protocol. The patient was mobilized on the first day after surgery and discharged on the fifth day with neurological improvement (VAS=1). The patient was followed up for a period of six months, and no further complications were observed. Surgeons must use caution while tightening the screw nuts, as not doing so may result in additional surgeries and complications for the patient in the future. The "two-three click" protocol for screw stabilization is an effective method for minimizing the issues associated with inner loosening and rod migration.

Novel uniplanar pedicle screw systems applied to thoracolumbar fractures: a biomechanical study

Objective: In this study, the advantages of the internal fixation configuration composed of uniplanar pedicle screws in the treatment of thoracolumbar fractures were verified by biomechanical experimental methods, which provided the basis for subsequent clinical experiments and clinical applications. Methods: A total of 24 fresh cadaveric spine specimens (T12-L2) were utilized to conduct biomechanical experiments. Two different internal fixation configurations, namely, the 6-screw configuration and the 4-screw/2-NIS (new intermediate screws) configuration, were tested using fixed-axis pedicle screws (FAPS), uniplanar pedicle screws (UPPS), and polyaxial pedicle screws (PAPS) respectively. The spine specimens were uniformly loaded with 8NM pure force couples in the directions of anteflexion, extension, left bending, right bending, left rotation, and right rotation, and the range of motion (ROM) of the T12-L1 and L1-L2 segments of the spine was measured and recorded to access biomechanical stability. Results: No structural damage such as ligament rupture or fracture occurred during all experimental tests. In the 6-screw configuration, the ROM of the specimens in the UPPS group was significantly better than that of the PAPS group but weaker than those of the FAPS group (p < 0.01). In the 4-screw/2-NIS configuration, the results were identical to the biomechanical test results for the 6-screw configuration (p < 0.01). Conclusion: Biomechanical test results show that the internal fixation configuration with UPPS can maintain the stability of the spine well, and the results are better than that of PAPS. UPPS has both the biomechanical advantages of FAPS and the superiority of easy operation of PAPS. We believe it is an optional internal fixation device for minimally invasive treatment of thoracolumbar fractures.

Biomechanical evaluation of a short-rod technique for lumbar fixation surgery

Objective: The purpose of this study was to analyze the stability and instrument-related complications associated with fixation of the lumbar spine using the Short-Rod (SR) technique.

Methods: Using finite element analysis, this study assessed the stability of a bilateral lumbar fixation system when inserting the pedicle screws at angles of 10°, 15°, and 20° to the endplate in the sagittal plane. Using the most stable construct with a screw angle, the model was then assessed with different rod lengths of 25, 30, 35, and 45 mm. The optimal screw inclination angle and rod length were incorporated into the SR model and compared against traditional parallel screw insertion (pedicle screws in parallel to the endplate, PPS) in terms of the stability and risk of instrument-related complications. The following parameters were evaluated using the validated L4–L5 lumbar finite element model: axial stiffness, range of motion (ROM), stress on the endplate and facet joint, von-Mises stress on the contact surface between the screw and rod (CSSR), and screw displacement.

Results: The results showed that the SR model with a 15° screw inclination angle and 35 mm rod length was superior in terms of construct stability and risk of complications. Compared to the PPS model, the SR model had lower stiffness, lower ROM, less screw displacement, and lower stress on the facet cartilage, the CSSR, and screws. However, the SR model also suffered more stress on the endplate in flexion and lateral bending.

Conclusion: The SR technique with a 15° screw inclination and 35 mm rod length offers good lumbar stability with a low risk of instrument-related complications.

Deviating from the Recommended Torque on Set Screws Can Reduce the Stability and Fatigue Life of Pedicle Screw Fixation Devices

Background and Objectives: Using an appropriate torque to tighten set screws ensures the long-term stability of spinal posterior fixation devices. However, the recommended torque often varies between different devices and some devices do not state a recommended torque level. The purpose of this study is to evaluate the effect of set screw torque on the overall construct stability and fatigue life. Materials and Methods: Two commercial pedicle screw systems with different designs for the contact interface between the set screw and rod (Group A: plane contact, Group B: line contact) were assembled using torque wrenches provided with the devices to insert the set screws and tighten to the device specifications. The axial gipping capacity and dynamic mechanical stability of each bilateral construct were assessed in accordance with ASTM F1798 and ASTM F1717. Results: Increasing or decreasing the torque on the set screw by 1 Nm from the recommended level did not have a significant effect on the axial gripping capacity or fatigue strength of Group A (p > 0.05). For Group B, over-tightening the set screw by 1 Nm did cause a significant reduction in the fatigue strength. Conclusions: Excessive torque can damage the rod surface and cause premature failure. When insertion using a manual driver is preferred, a plane contact interface between the set screw and rod can reduce damage to the rod surface when the set screw is over-torqued.

A biomechanical investigation of the retentive force of pedicle screw structures for different screw tulip designs

BACKGROUND

Pedicle screw based spinal fixation systems have been widely used for treating a variety of spinal diseases. The retentive force is an important factor that determines structural stability. The screw tulip design and the magnitude of nut tightening torque influence the retentive force. This study investigated the influences of varied tilt angles between the shaft-rod interface and varied nut tightening torques on the retentive force of the monoaxial, polyaxial, and uniplanar screws.

METHODS

Three types of tulip constructs were biomechanically tested. Two parameters that affect the retentive force include the tilt angle and the nut tightening torque. The retentive force was investigated by an axial gripping capacity test and axial torque gripping capacity test.

FINDING

Among all combinations of screw designs and tilt angles, the 12 Nm nut tightening torque offered a greater retentive force than the 8 Nm, except for monoaxial screws with a 0 degree tilt angle. For monoaxial screws, the retentive force was negatively correlated with increasing tilt angles. For polyaxial and uniplanar screws, the retentive forces remained constant with increasing tilt angles.

INTERPRETATION

In monoaxial screws, when the axis of the shaft isn't perpendicular to the axis of the rod, a gap is formed between the tulip-rod interface. This results in a decreased retentive force. In polyaxial and uniplanar screws, the contact surfaces were the same in different tilt angles, therefore, the retentive force remained constant, which was attributed to the adjustable tulips always being perpendicular to the axis of the rods.

A biomechanical investigation of different screw head designs for vertebral derotation in scoliosis surgery

BACKGROUND CONTEXT

The posterior pedicle screw-rod system, which is widely used to correct spinal deformities, achieves a good correction rate in the frontal and coronal planes but not in the axial plane. Direct vertebral derotation (DVD) was developed to correct axial plane deformities. However, the design of screw head and body connection, in terms of monoaxial, polyaxial, and uniplanar screw, may influence the efficiency of DVD.

PURPOSE

This study compared the efficiency of a newly designed uniplanar screw with that of monoaxial and polyaxial screws in the DVD maneuver.

STUDY DESIGN

A porcine spine model and monoaxial, polyaxial, and uniplanar screws were used to examine the biomechanics of the DVD maneuver.

METHODS

Six T7-T13 porcine thoracic spine segments were used as test specimens in this study. Pedicle screws were inserted in the left pedicles of the T9-T11 spinal segments and then connected with a rod. Three types of pedicle screws with different screw head designs (monoaxial, polyaxial, and uniplanar) were employed in this study. The material testing system (MTS) machine generated a rotational moment through the derotational tube on the T10 (apical body) pedicle screw, which simulated the motion applied during the surgical vertebral derotational procedure. The pedicle strain and the kinematics of the vertebral body and derotational tube were recorded to evaluate the derotational efficiency of different pedicle screw head designs.

RESULTS

The variances of the derotation for the monoaxial, polyaxial, and uniplanar screws were 2.22°±1.43°, 32.23°±2.26°, and 4.75°±1.60°, respectively; the derotation efficiency was 0.65, 0.51, and 0.12, respectively, when the torques of the spinal constructs reached 3 Nm. The rotational variance of the polyaxial screw was statistically greater than that of the monoaxial and uniplanar screws (p<.05). The maximum micro-strains of the pedicles for the monoaxial, polyaxial, and uniplanar screws were 1,067.45±550.35, 747.68±393.56, and 663.55±271.04, respectively, with no statistically significant differences (p>.05).

CONCLUSIONS

The screw head design played an important role in the efficiency and variance of the derotation during the DVD maneuver. The derotational efficiency of the newly designed uniplanar screw was closer to that of the monoaxial screw group than to that of the polyaxial screw group. The polyaxial screw was inferior to DVD owing to a derotational variance between the derotational tube and the apical body that was correlated with the range of motion of the screw head. In the present study, the pedicle strain was similar in all groups. However, the pedicle strain of the uniplanar screw group was lower than that of the monoaxial screw group and was similar to that of the polyaxial screw group when the angle of rotation of the apical body increased.

Traumatic dislocation of the S1 polyaxial pedicle screw head: a case report

Polyaxial screw head dislocation in the absence of a manufacture defect is extremely rare and represents a biomechanical overload of the screw, leading to early failure. A 58-year-old gentleman underwent instrumented fusion using polyaxial pedicle screws-titanium rod construct with interbody cage for spondylolytic spondylolisthesis at the L5/S1 level. He attempted to bend forward ten days after the surgery which resulted in a dislocation of the right S1 polyaxial screw head from the screw shank with recurrence of symptoms. He underwent revision surgery uneventfully. This case highlights the need to pay particular attention to the strength of fixation and the amount of release to avoid such a complication.

How does a novel monoplanar pedicle screw perform biomechanically relative to monoaxial and polyaxial designs?

BACKGROUND

Minimally invasive spinal fusions frequently require placement of pedicle screws through small incisions with limited visualization. Polyaxial pedicle screws are favored due to the difficulty of rod insertion with fixed monoaxial screws. Recently, a novel monoplanar screw became available that is mobile in the coronal plane to ease rod insertion but fixed in the sagittal plane to eliminate head slippage during flexion loads; however, the strength of this screw has not been established relative to other available screw designs.

QUESTIONS/PURPOSES

We compared the static and dynamic load to failure in polyaxial, monoaxial, and monoplanar pedicle screws.

METHODS

Six different manufacturers' screws (42 total) were tested in three categories (polyaxial, n = 4; monoaxial, n = 1; monopolar, n = 1) utilizing titanium rods. An additional test was performed using cobalt-chromium rods with the monopolar screws only. Screws were embedded into polyethylene blocks and rods were attached using the manufacturers' specifications. Static and dynamic testing was performed. Dynamic testing began at 80% of static yield strength at 1 Hz for 50,000 cycles.

RESULTS

In static testing, monoaxial and monoplanar screws sustained higher loads than all polyaxial screw designs (range, 37%-425% higher; p < 0.001). The polyaxial screws failed at the head-screw interface, while the monoaxial and monoplanar screws failed by rod breakage in the static test. The dynamic loads to failure were greater with the monoplanar and monoaxial screws than with the polyaxial screws (range, 35%-560% higher; p < 0.001). With dynamic testing, polyaxial screws failed via screw-head slippage between 40% and 95% of static yield strength, while failures in monoaxial and monoplanar screws resulted from either screw shaft or rod breakage.

CONCLUSIONS

All polyaxial screws failed at the screw-head interface in static and dynamic testing and at lower values than monoaxial/monoplanar screw designs. Monoplanar and monoaxial screws failed at forces well above expected in vivo values; this was not the case for most polyaxial screws.

CLINICAL RELEVANCE

Polyaxial screw heads slip on the screw shank at lower values than monoaxial or monoplanar screws, and this results in angular change between the rod and pedicle screw, which could cause loss of segmental lordosis. The novel monoplanar screw used in this study may combine ease of rod placement with sagittal plane strength.

Failure of Monoaxial Pedicle Screws at the Distal End of Scoliosis Constructs: A Case Series

BACKGROUND

The goals of instrumented fusion for scoliosis are to correct deformities, stabilize the spine, and achieve arthrodesis. Monoaxial pedicle screws are often used in scoliosis constructs and have shown superiority over other types of pedicle screws in their ability to correct vertebral rotation and lumbar lordosis. However, because of the fixed-angle nature of the monoaxial pedicle screw head, any malalignment at the rod-screw interface could result in less than optimum stability.

RESULTS

This series exhibits 3 cases of set screw loosening with the use of monoaxial pedicle screws at the distal end of long spinal fusion constructs for the management of patients with scoliosis; these complications all occurred within 6 months of the index procedures. The results of a detailed microscopic analysis of the failed components from 1 of the cases are also presented.

CONCLUSIONS

From this evidence, the authors of the current study recommend that surgeons exercise caution when using monoaxial pedicle screws at the distal end of long spinal fusion constructs, especially after compression has been achieved on the convex portion of the curve.

Would CoCr rods provide better correctional forces than stainless steel or titanium for rigid scoliosis curves?

STUDY DESIGN

Comparative in vitro, biomechanical study.

OBJECTIVE

Compare the effect of rod curvature and material properties on rod flattening and correctional forces.

SUMMARY OF BACKGROUND DATA

Traditional methods of correction for large progressive deformities involve 3-dimensional correction, performed with an attempt to reach a balanced correction in all planes, spinal instrumentation, and fusion. Increasing attention to the transverse plane correction has developed after the introduction of segmental pedicle screws into the treatment of idiopathic scoliosis. Approximation of the spine (pedicle screws or hooks) to the rods remains the heart of many deformity procedures. Therefore, it is crucial that the instrumentation used provide and maintain the initial correction of the spinal deformity while minimizing potential intraoperative failures.

METHODS

Two experiments were performed using 80 rods made from 4 different materials namely: stainless steel (SS), titanium (Ti), cobalt chromium (CoCr), and ultrahigh strength stainless steel (UHSS). Half of the rods were contoured to 20 degrees, whereas the reaming contoured to 30 degrees. Half of the rods were approximated to a synthetic spine models to measure the flattening of the rods when approximated to highly rigid spine. The other half was used to measure the correctional forces produced by each rod type and curvature.

RESULTS

For the 20-degree pre-bend rods, Ti was the best in maintaining its original shape followed by UHSS, SS, and CoCr of 90%, 77%, 62.5%, and 54.4%, respectively. The 30-degree pre-bend showed exactly a similar trend with 80.7% for Ti, 71% for UHSS, 54.6% for SS, and 48.1% for the CoCr rods. For 30-degree pre-bend CoCr and UHSS rods, the intraoperative reduction forces were almost 42% and 10% higher than the Ti and SS rods, respectively. The correctional force produced by the Ti 30-degree pre-bend rod was approximately 67% that of a CoCr and UHSS rods.

CONCLUSIONS

CoCr and UHSS rods have the ability to produce the highest correction forces, however, both can plastically deform in a very rigid curves. Therefore, it is critical to have sense of the quality of the bone fixation as well as the curve flexibility when selecting for appropriate rod size material and contouring the rod to the desired shape.

The effect of screw head design on rod derotation in the correction of thoracolumbar spinal deformity: laboratory investigation

OBJECT

The use of fixed-axis pedicle screws for correction of thoracolumbar deformity in adult surgery is demanding because of the challenge of assembling the bent rod to the screw in order to achieve curve correction. Polyaxial screw designs, providing increased degrees of freedom at the screw-rod interface, were reported to be insufficient in achieving correction of thoracic deformity in the axial plane. Using a multisegment bovine calf spine model, this study investigated the ability of a new uniplanar screw design to achieve derotation correction of the vertebrae and maintain a degree of correction comparable to that of fixed-axis and polyaxial screw designs.

METHODS

Eighteen calf thoracolumbar spine segments from T-6 to L-1 (n = 6 per screw design) underwent bilateral facetectomies at the T9-11 levels and were instrumented bilaterally with pedicle screws and rods. To assess the efficacy of each screw design in imparting rotational correction, each instrumented level was tested under applied torsional moments designed to simulate the motion applied during derotation surgery. Once rotation was achieved, the whole spine was tested to assess the overall stiffness of the construct.

RESULTS

The fixed-axis construct showed increased efficacy in imparting rotation compared with the uniplanar (115% increase, p > 0.05) and polyaxial (210% increase, p < 0.05) constructs. Uniplanar screws showed a 21% increase in torsional stiffness compared with the polyaxial screws, but this difference was not statistically significant.

CONCLUSIONS

The design of screw heads plays a significant role in affecting the rotation of the vertebrae during the derotation procedure. Uniplanar screws may have the advantage of maintaining construct stiffness after derotation.

Design and performance of spinal fixation pedicle screw system

Pedicle screw-rod bilateral constructions are extensively used in spinal fixation. In this study, the common cause for failure of bilateral constructions has been determined to be the high stress concentration at the rod–setscrew interface. In order to overcome this problem, a design modification has been made by using a supplementary part (shoe) between rod and setscrew. Performance comparison of the conventional design and modified design has been done by conducting static tests. Design modification has resulted in 11%, 27%, 42% and 31% improvements in axial gripping capacity, torsional gripping capacity, flexion/extension resistance and subassembly compression strength, respectively. The most outstanding achievement has been obtained in the fatigue life, which was extended by almost three times.