Zpacks Arc Haul Ultra 60L Review (2026)

By Grant — Last updated 2026-07-03 — backpacks

Grant's Verdict

9/10 — Best in Class

Zpacks Arc Haul Ultra 60L uses Dyneema Composite Fabric (DCF) with curved carbon fiber stays that provide a structured, curved frame at sub-2-lb weight. It's the lightest proper load-bearing backpack available — carrying 25-35 lbs comfortably despite weighing less than some water bottles.

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AFFILIATE DISCLOSURE: Links in this review are Amazon affiliate links — we earn a small commission at no extra cost to you. Our ratings are never influenced by commission rates.

The Short Version

Zpacks Arc Haul Ultra is the go-to ultralight pack for thru-hikers reducing base weight below 10 lbs. We tested carbon frame stability under 30-lb loads and compared it to frameless alternatives.

Who This Is For

Buy this if: Thru-hikers with base weights under 12 lbs who want structured carry without traditional frame weight.

Skip this if: Traditional heavy packers — the DCF material is unforgiving with overpacking and the load limit is 35 lbs comfortable maximum.

Pros & Cons

Pros

  • 1 lb 5 oz for a 60L structured pack — nothing competes
  • DCF is waterproof and incredibly tear-resistant for its weight
  • Carbon fiber arc stays create hip transfer for loads up to 35 lbs

Cons

  • $600+ — significant investment
  • DCF doesn't stretch — fit must be perfect; returns are expensive from a direct brand
  • Limited adjustability vs. traditional packs

The Detailed Breakdown

DCF Construction

Dyneema Composite Fabric is a laminated sheet material that's both lighter than and stronger than nylon or polyester. It's waterproof (no seam sealing required), puncture-resistant, and ultra-low-weight. The trade-off: it doesn't stretch or conform like woven fabrics, so the pack's shape is fixed — correct sizing and fit are non-negotiable.

Grant's Final Take

Buy it if you're serious about ultralight thru-hiking. Rent or borrow first to confirm fit before committing the price.

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Frequently Asked Questions

Is DCF safe to use in the rain?
Yes — DCF is fully waterproof. No pack cover needed; seams are welded rather than sewn, eliminating the usual leak points.
What's the load limit?
Zpacks recommends 35 lbs maximum. Above this, the carbon stays flex and the hipbelt loses transfer efficiency.

Methodology: Our gear ratings are based on community research across r/camping, r/hiking, r/ultralight, r/backpacking, and r/CampingandHiking, combined with manufacturer specifications and verified owner feedback. We analyze Reddit consensus, common failure patterns reported across multiple platforms, and long-term durability reports. Grant rates based on value, packability, durability, and whether it would survive a trip he's been planning to take for three years. Last verified 2026-07-03.

Affiliate disclosure: This review contains Amazon affiliate links. If you purchase through these links, Gear Made Simple earns a small commission at no extra cost to you.