Laminate vs. Traditional Horse Rug Fabrics: How Performance Liners Are Changing the Game

What's Currently on the Market?

Traditionally, most turnout rugs are made from a PU-coated fabric. The face fabric typically ranges from 300 denier to 1680 denier (with one brand even offering 1800 denier).

This creates a fairly robust outer layer, which is then combined with insulation and a lining to complete the rug.

But let’s take a closer look at how coated fabrics are made — and what they actually offer in terms of performance.

Traditional Coated Fabrics

Most horse rug fabrics are coated with hydrophilic polyurethane (PU). This coating provides a basic level of waterproofing and a degree of breathability. However, balancing those two properties is challenging: the more waterproof a fabric is, the less breathable it tends to be.

For basic or budget waterproof garments, coated fabrics work well — especially if they're not designed to be worn for long periods. But horse rugs are different. Horses often wear the same rug for hours, days, or even weeks. So we had to ask: Is a coated fabric really the best choice?

Let’s Get a Bit Technical...

PU coatings are hydrophilic, which literally means “water-loving.”

These coatings absorb moisture — whether from rain or sweat — and rely on evaporation to release it. But when saturated, the coating swells and can create condensation inside the rug.

Years ago, coated fabrics were good enough. But with increasingly wet and mild winters, many coatings struggle to balance waterproofing and breathability. This results in discomfort — and potentially impacts your horse’s well-being.

The Environmental Impact

Another major drawback? Coated fabrics are nearly impossible to recycle. Once PU is applied to a nylon or polyester face fabric, it creates a composite material that cannot be easily separated — making recycling impractical.

Why We Created the Performance Liner

There’s a better way to achieve both waterproofness and breathability — and that’s through laminated fabrics. Also called membrane fabrics, laminates are widely used in premium outdoor apparel.

As a fabric technologist with over 20 years of experience developing waterproof, breathable materials for outdoor brands, I haven’t used a coated fabric in a collection since 2004.

Let’s explore how laminated fabrics work — and why they’re ideal for horse rugs.

How Laminated Fabrics Work

A laminate is created by applying a thin membrane film to the back side of the fabric. Laminates can use different technologies:

1. Hydrophilic – Like coated fabrics, they manage moisture through absorption and evaporation.

2. Microporous – These have microscopic pores that let sweat vapor escape while blocking water droplets.

3. Hybrids – A combination of both technologies.

Hydrophilic laminates work similarly to PU coatings but offer much higher performance, as the laminate film is thinner and quicker at managing moisture.

Microporous membranes are highly breathable and waterproof, though slightly more difficult to bond to some heavy fabrics.

Sustainability Bonus

Laminates can be made from polyurethane, polyester (PET), or polypropylene. When the laminate shares the same chemical structure as the face fabric (e.g., polyester + polyester), it’s easier to recycle — supporting a more circular product lifecycle.

So Why Aren’t Laminates Common in Horse Rugs?

It’s simple: Laminating heavy-duty fabrics (like 1200D or 1680D) is difficult. The laminate film is very thin and gets abraded by the coarse outer fabric, causing it to break down.

Our Solution: The Performance Liner

That’s why we created the Performance Liner — a game-changing innovation for horse rugs.

It’s made using a 3-layer laminated fabric, designed to deliver high levels of waterproofing and breathability, while staying light, supple, and comfortable for your horse.

We also enhance the liner with:

• Packable soft insulation

• Anti-static properties

• Anti-microbial technology (which inhibits bacteria and fungus)

This maximizes both performance and comfort — even during long wear in challenging conditions.

The Result?

A true innovation that redefines how turnout rugs are made. Our Performance Liner is a key component of our patent-pending Cirra Rug — and it’s designed to meet the demands of modern equine care and climate challenges.

Final Thoughts

Coated fabrics had their place. But horses deserve better.
The future of horse rugs lies in performance-focused, recyclable, laminated fabrics — and we’re proud to be leading that evolution.