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The incidence of achilles ruptures is increasing, probably due to the increase in sports and exercise amongst an older population.
Whether its treated surgically or conservatively, the recovery is prolonged and it will take 8-10 months to return to full activity and sports and over a year to reach maximum recovery. The goal of treatment is to achieve maximum function in the calf muscles and this requires intensive input from physiotherapy and from the patient to achieve this.
We know from the original papers by Mason & Allen in 1948, that tendons heal quickest and strongest if they are immobilised for a short period and then mobilised within a protected environment. This is the focus of current achilles rupture management. We also know that early weightbearing is not detrimental if the ankle is protected in plantarflexion.
It is important to know the severity of the injury and ultrasound is the investigation of choice – it will confirm the site of rupture and also the presence of any gap in the tendon ends. Ruptures at the proximal muscul0tendinous junction do not require surgery and should be treated conservatively (surgery may still be indicated in professional athletes). Ruptures or avulsions at the distal end usually require surgery as there is often a large gap. This will require open surgery (see achilles avulsion).
Most ruptures occur in the midportion 6-7cm above the insertion and the ultrasound will confirm most importantly if the tendon ends appose in plantarflexion. Recent studies have shown that little or no benefit with surgery in patients where there is a gap <5mm and these can be successfully treated in a well structured rehabilitation programme with protection in an equinus cast or boot, with reducing equinus over several weeks. If there is a significant gap >5mm then, in my opinion, surgery is required although some surgeons use >10mm gap as the cut off.
In professional athletes or where maximal achilles function is essential for work, I recommend surgical repair – long term function studies have confirmed significant benefits in plantarflexion torque with surgery.
Ideally, the surgery should be performed using minimally invasive techniques – these have been shown to have significantly lower risks of wound and infective complications, when compared to open surgery. The technique described here is one method – there are others that use jigs to guide the suture placement (Achillon and PARS devices)
Readers will also find the following OrthOracle techniques of interest:
Achilles tendon rupture: Integra Achillon percutaneous repair.
Achilles tendon rupture: Open repair technique.
Achilles Reconstruction :Flexor Hallucis Longus tendon transfer using Arthrex Biotenodesis screw
Achilles avulsion: Reattachment using an Arthrex Biocomposite anchor.
Grassi et al. Minimally Invasive Versus Open Repair for Acute Achilles Tendon Rupture: Meta-Analysis Showing Reduced Complications, with Similar Outcomes, After Minimally Invasive Surgery. J Bone Joint Surg Am. 2018

INDICATIONS
Acute rupture of the Achilles tendon, with a demonstrable gap of >5mm on ultrasound assessment, in full plantarflexion. It is not suitable for avulsion injuries.
The technique is suitable for injuries 3 weeks old and potentially longer, although an open repair should be planned for too. If the tendon ends are too stuck down or retracted, it may not be possible to perform a percutaneous repair – in which case it’s necessary to extend the incision proximally and distally for an open reconstruction.
In professional athletes or highly athletic patients, I preferentially recommend acute repair as there is strong evidence that power (plantarflexion torque) is better with surgery.
SYMPTOMS & EXAMINATION
The classic patient is a male between the ages of 25 and 55 years who is involved in a sports activity, commonly squash and tennis in the UK. The patient often feels as though they had been “hit from behind by another player” and may also have heard a large pop or rifle shot.
The leg is instantly weak and the patient no longer able to play any sport and struggles to walk. Surprisingly it’s often quite painless.
The most common site of rupture is in the mid portion 6-7cm above the insertion but its important to check for tears high up in the muscle tendon junction and low tears or avulsions as the treatment is very different and MI surgery not applicable.
Examination is best performed with the patient lying prone on the couch, with the feet resting off the end of the couch. This allows a relaxed resting position and will demonstrate the natural tension in the calf. On the intact side, there will be 10-15 degrees of plantarflexion – on the rupture side the foot will hang vertically downwards. This is the Achilles Tendon Resting Angle (ATRA). There will also be loss of the normal outline of the tendon when compared to the normal side and there may be a clear gap visible. Gentle palpation may reveal a gap in the tendon, but this is often obscured by swelling. The achilles is often quite tender over a diffuse area and this is not specific.
There are other tests used such as the Thompson test or calf squeeze test – Squeezing the calf muscle should cause plantarflexion, indicating an intact Achilles on the normal limb. On the injured side, there is no motion. I don’t find this as reliable as the resting posture test, as often its too painful to squeeze it as hard and often the injured side moves a little anyway.
IMAGING
Determination of the site of rupture is essential because ruptures proximal to the myotendinous junction do not require operative intervention and distal avulsions need a different reconstruction.
Ultrasound is the investigation of choice. It allows assessment of the tendon quality (revealing underlying tendinopathy), the site of the rupture (the distance from the insertion on the calcaneus) and especially whether or not the tendon ends can be opposed. It will confirm if the injury is suitable for a minimally invasive repair – that it is not an avulsion injury or rarely when there is a large longitudinal injury.
MRI is also very helpful, especially for determining the height of the rupture – in proximal / musculotendinous tears non-operative treatment may be preferred. However it is not possible to be dynamic and so no assessment of the tendon approximation can be made.
Often an MRI has been organised by the referring team already – I use ultrasound much more than MRI, but I do use it in cases of extensive swelling, where the nature of the injury is unclear.
In general, I use ultrasound to confirm that the tendon ends come together, in patients that I am considering treating non-operatively. I use MRI in patients when I am not confident about the type of the rupture or when I suspect that the quality of the tendon may be poor and not suitable for surgery.
ALTERNATIVE OPERATIVE TREATMENT
Open achilles repair.
This is the old gold standard and is used less and less now, due to the increased risks of wound problems and nerve injury.
Percutaneous operative repair techniques:
Several techniques have been described with no particular technique gaining widespread use (Achillon / PARS device). The Achillon jig, passes transverse sutures across the tendon and the PARS is similar but with a locking loop mechanism. I have used both devices and had issues with poor suture hold in the proximal tendon, with the sutures pulling out easily. Although small, there is an incidence of sural injury with these transverse sutures.
Because of these issues, I use a percutaneous medial locking suture instead. In my hands, the suture fixation is better and it less invasive – the primary incision is much smaller. Also, the incisions are away from the sural nerve.
Achilles reconstruction procedures
Used for delayed presentation of more than 6 weeks. These are used when the tendon gap cannot be brought together primarily.
The V-Y plasty or Achilles turn-down technique involve mobilising part of the proximal muscle / tendon unit to bridge the gap.
FHL tendon transfer – either long or short. This uses the powerful FHL muscle to provide plantarflexion of the ankle by transferring it to the heel. Either by direct implantation into the calcaneum (Short FHL transfer) or passing it through the heel and proximally to attach to the proximal achilles (Long FHL transfer).
NON-OPERATIVE MANAGEMENT
Recent studies in the literature support the treatment of closed acute Achilles tendon ruptures with opposable tendon ends in a weight bearing walker boot. The boots either have adjustable hinges at the ankle to vary the degree of equinus or, more commonly, removable wedges can be applied within the boot to adjust the foot position.
CONTRAINDICATIONS
The absolute contraindication for surgical repair of an Achilles rupture is in patients with poor lower limb vascularity and active infections. Patients with underlying neuropathy and diabetes should also be preferentially managed non-operatively. Any patient taking medications that compromise the immune response to trauma (steroids, DMARDS etc) should avoid surgical repair.
The quality of the skin also needs to be considered carefully for increased risks of infective complications. Any signs of skin disease or infection indicates that surgery may not be safe.

The surgery is performed under general or spinal anaesthesia, with a thigh tourniquet (300 mmHg) and the patient in the semi-prone position.
The semi-prone position is really useful for surgery on the achilles or the posterior ankle – it is much less complicated for the anesthetist and also easier for the theatre team to set up than fully prone.
The patient is placed in the lateral position with the injured leg on the bottom and just off the end of the table. The patient is then rolled forwards onto a large pillow or bolster and the back supported. The lower leg is then pulled behind gently to allow it to roll in. Remember to put the tourniquet on before your turn the patient!
One dose of IV antibiotics given at induction.

There are many advantages to minimally invasive achilles repair, with very low risks of infection, nerve injury and rerupture. The post operative rehabilitation follows other well published regimens, with protection in a backslab plastcast for 2 weeks to promote good wound healing and avoid infection. This is followed by a period of partial, then full weightbearing in a specialised Achilles boot with reducing equinus over 8 -10 weeks.
I use the Vacoped Achilles boot which provides dynamic equinus in a protected range of plantarflexion. I prefer this , as it allows greater movement and potentially faster healing. My colleagues use a long leg orthopaedic boot with static equinus wedges, with equal success.
The first 2 weeks are non-weightbearing in the plastercast with strict elevation above hip height for 45mins/hour. Clinic review is at 2 weeks and the immobilisation changed to the vacoped achilles boot, locked in full plantarflexion. Partial weightbearing (50% body weight) is started. The boot is worn day and night but can be taken off for short periods when resting or for physiotherapy.
Physiotherapy starts at 2 weeks – initially this is simple soft tissue mobilisation and massage with minor unresisted dorsiflexion / plantarflexion exercises.
Note: Dorsiflexion will come naturally and its extremely important the physiotherapists do not perform dorsiflexion stretches!
There is a significantly increased risk of Deep Vein Thrombosis (DVT) with achilles tendon rupture and also with surgical repair. Therefore oral anticoagulation is given for the first 4 weeks to reduce the risk of DVT.
At 4 weeks full weightbearing is started and the boot can be taken off at night and at rest. An increasing physiotherapy loading programme is started.
WEEKS 2-4: Partial Weight Bearing in Vacoped Boot
Partial WB of 50% of body weight allowed – test how this feels like on a bathroom scales.
CHANGE TO VACOPED ACHILLES BOOT
locked in full plantarflexion.
wear 24 hrs a day.
can take off when sitting.
↑ df range by 1 notch per week (5 per week)
PHYSIOTHERAPY STARTS – NO DORSIFLEXION STRETCHES AT ANY STAGE
Soft tissue massage
Gentle Active
Work on Achilles gliding
WEEKS 4-8: Fully Weight Bearing in Vacoped boot
remove walker at night.
↑ dorsiflexion by 1 notch per week.
discard crutches when able
zero position at 8 weeks – change to flat sole
PHYSIOTHERAPY
Active Plantarflexion with Theraband
Compex muscle stimulation if available
Seated heel raises
Full PF, inversion and eversion
At 6 weeks start light NWB aerobic exercises –
e.g. cycling (push with heel, not toes)
WEEKS 8-12: Vacoped to Shoes with heel raise
discard vacoped at +10’
change to flat shoe with 1cm heel raise for 4 weeks
PHYSIOTHERAPY
Proprioception/balance work
Gait re-education
Ecc/Con loading (bilat to single. Emphasise ecc phase)
Single stairs
Progress to upslope and downslope.
WEEKS 12-16: NORMAL SHOES.
PHYSIOTHERAPY
Progressive exercises
Full NWB work eg Xtrainer / Bike
WEEKS 16-24+
PHYSIOTHERAPY
Progress to Jogging then fast acc. & deceleration.
Directional running / cutting
Pylometrics. e.g. toe bouncing upwards / forwards /directional

Operative treatment versus nonoperative treatment of Achilles tendon ruptures: systematic review and meta-analysis.
Ochen et al BMJ. 2019
A meta-analysis of 10 randomised controlled trials and 19 observational studies with over 16,000 patients. In conclusion, re-rupture is less with operative repair although this included low risks of surgical complications. Early weightbearing (less than 4 weeks) was not harmful.
The Rate of Healing of Tendons – An experimental study of tensile strength Mason, M & Allen, H
Annals of Surgery 1941
The original and classic paper on tendon healing performed on dogs. There were 3 groups, each with surgically cut flexor tendons and differing rehabilitation methods. The dogs were then sacrificed at different stages and the tendon strength examined. Group A were repaired and the limb left unprotected, Group B were temporarily immobilised and Group C were immobilised throughout. The findings showed that a period of immobilisation and protection for 2-3 weeks followed by active movement provided the greatest repair strength and healing.
The treatment of a rupture of the Achilles tendon using a dedicated management programme. P Williams et al. BJJ 2015
The SMART trial – A controlled trial of conservative (211) versus surgically treated (62) achilles ruptures. This concluded that closely monitored non-operative management (in patients with <10mm gap on ultrasound) had a comparable re-rupture rate to surgical cases and in an smaller group of patients (incomplete participation), there was no functional difference. This a good paper and has a very nice rehabilitation protocol outlined but its conclusion is perhaps misleading regarding the outcome as only a small number (103) were able to complete functional assessment.
The treatment of a rupture of the Achilles tendon using a dedicated management programme. P Williams et al. BJJ 2015
The SMART trial – A controlled trial of conservative (211) versus surgically treated (62) achilles ruptures. This concluded that closely monitored non-operative management (in patients with <10mm gap on ultrasound) had a comparable re-rupture rate to surgical cases and in an smaller group of patients (incomplete participation), there was no functional difference. This a good paper and has a very nice rehabilitation protocol outlined but its conclusion is perhaps misleading regarding the outcome as only a small number (103) were able to complete functional assessment.
A Prospective Randomized Trial Comparing Surgical and Nonsurgical Treatments of Acute Achilles Tendon Ruptures. Juhana Leppilahti et al. AJSM 2016
A randomised controlled trial of operative vs non operative achilles ruptures (60 patients). Strength, as measured by peak torque was 10-18% greater in the operative group at 18 months. This is a good paper written by Leppilahti who is an under-recognised expert on the achilles.
Reference
- orthoracle.com






































