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Werd. It's all in how one packs it, and in how well the stays are molded to your back. The model Catalyst I have, a 2010 model, has a very dense foam used in the lower back area which could certainly be uncomfortable at 40lbs if not fitted well using the stays. I happen to think my Catalyst a fine pack for 40-pound loads, but this may be a function of many factors. For reference, I'm 6'-1", 165lbs, and my pack has a medium-torso and small belt. The Catalyst replaced a Golite Infinity, which replaced a Peak 1 Kevlar/Polymer external frame, as my 75%-of-the-time pack. In such a role, I do like the Catalyst more than the other two packs I listed.
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