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Stage Riggingand the Five Deadly Sins

(or if it looks wrong it probably is wrong)

The care and maintenance of rigging systems

is one of the most important safety concerns in

any performance space. Ongoing maintenance

must be a process that continues between

regularly scheduled inspections.

Our Commitment - Ontario Staging is commited to supplying the best products and services and keeping abreast of the rapidly changing technologies and innovations in the entertainment world. We convey this information to our customers through our designs, products and educational seminars to make our industry safer and exciting.

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Stage Rigging and the Five Deadly Sins (or if it looks wrong it probably is wrong)

As Riggers and Technicians we move equipment and scenic elements overhead on a regular basis. This requires a higher level of diligence and care in a workplace that is often changing and fast paced. Below are the five most common hazards in theatrical rigging. They are meant as guidelines forn implimenting a comprehensive safety program.

Unrated HardwareIt is essential that the Safe Working Load (SWL) of all components in a system are known and that the Safe Working Load for

the weakest component is not exceeded. Hardware that does not have the SWL clearly forged into it is a “wild card”. Most industrial applications work on a SWL of 5:1. A component that will fail under a load of 5000 lbs. that is given a safety factor of 5:1 has an SWL of 1000 lbs. In the entertainment industry an SWL of 8:1 is the accepted standard.

Incomplete InstallationEven though a component may have a sufficient SWL rating, it becomes a liability if it is not installed correctly. Installations should be neat and clean with

hardware properly terminated. An installation that is neat and orderly allows for easier inspections and ensures that the forces on components, such as pulleys, are within the equipments design limits.

Damaged EquipmentA piece of damaged equipment becomes the weak link and a liability to the system as a whole. Damaged components must be replaced immediately with ones

that are of equal or greater rating. Replacing a broken part, even temporarily, with a substandard piece is putting the integrity of the system at risk.

Wear and TearEven the best of systems wear out. This is why it is essential for maintenance to be an ongoing process. The Ontario Labour Code requires yearly inspections

of all hoisting equipment. The owner must keep a maintenance and repair log. Since we are often lifting over head the operator must be aware of any changes in how the system is running and investigate the cause immediately to ensure that safe operation is not compromised.

Improper UseUsing equipment for purposes that it was not designed for, or modifying equipment for other purposes, can easily result in overloading and failure. Many

components also have strict guidelines as to how and where they should be used by the manufacturer. For example Spectrum 3 proof coil chain is suitable for suspending stationary loads, but, if the load will be moving a Spectrum 8 chain is required. It is important to ensure that the components are appropriate for the application.

“A lifting device shall be operated in such a way that, no part of a load passes over any worker”Ontario Occupation Health and Safety Act and Regulations for Industrial Establishments section 51 (2) b (i)

An unrated “eye bolt” has bent from overloading.

This improperly installed pulley allows the cable to rub on the side of the groove. The fleet angle should not exceed 2 degrees.

The thimble on the right has been overloaded to the point of being deformed. The thimble on the left is the correct shape. It is often helpful to compare components to confirm the degree of damage.

Signs of wear from everyday use can be subtle. The stands of the cable shown here began to break from 25 years of use.

A headblock is being used to divert cables horizontally. This imposes stresses on the bearings that they were not designed for.

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Rigging Inspection ChecklistCounterweight System

Set runs smoothly and quietlyPipe Batten is straight and level over its lengthLead cables terminated correctly at battenLead cables undamaged - no broken strands or birds nestingLead cables terminated at carriage topLoft blocks securely mounted and lead cables are not rubbing on building structureCarriage square and running true in guides without bindingCarriage properly weighted for loadHead block secure and fleet angles to loft blocks are under 2 degreesPurchase line not wornRope lock adjusted and operating properlyFloor tension block adjusted and operating properlyBottom stop rail intactWall frame and T-Channels are straight and plumb with no signs of wear pointsAll fasteners are tightenedLoading and fly floors are clear of obstacles and counterweights are neatly stacked

Motorized Rigging SystemsSet runs smoothly and quietlyPipe Batten is straight and level over its lengthLead cables terminated correctly at battenLead cables undamaged - no broken strands or birds nestingAll fleet angles less than 2 degreesLead cables terminated at carriage topLoft blocks securely mounted and lead cables are not rubbing on building structureWinch assembly is not leaking lubricantControl and power wiring neat and secure - no exposed conductorsSet stops at preset limitsAll operator stations functioning correctlyEmergency stop system operating correctlyPower disconnect switch with in reach of winch assemblyAll fasteners are tightened

Dead Hung (Stationary Rigging)Pipe battens are straight and level over its lengthSupport hardware is rated and correctly installedSupport points are not causing any discernable deflection in the building structureAll fasteners are tightened

Annual inspections should be completed by an experienced consultant.

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Ontario Staging Limited78 Mack Avenue, Scarborough, ON M1L 1M9

Tel: (416) 694-8980 • Fax: (416) 694-2979 • Toll Free: (877) 69STAGE

Ontario Staging LimitedOntario Staging Limited was established in 1987 to meet the growing demands of the theatrical and television industry. The company’s main focus involves the manufacturing and the installation of drapes and staging equipment.Ontario Staging Limited has a rental department stocking drapes, track, platforms and assorted lighting equipment. We are also a dealer for Rosco Laboratories, Lee Filters, Kee Klamps, H & H Track Systems, and Atlas Pipe.Tony Physentzou, president of Ontario Staging Ltd., has worked in the theatre and entertainment industry for the last 35 years. He has worked in many areas in his profession, including staging, lighting, and rigging installations.

Visit our showroom to pick up fabric samples and/or product literature relevant to your needs.

Notable Rigging InstallationsMotorized Rigging

Air Canada Centre • Motorized Winch, Lighting Pod and Concert Track SystemsHolt Renfrew Stores • Motorized Grid for Store Decor

CBC • Motorized Hoist System

Lighting Grids

Science Centre, Human Arcade Room/Communication Hall • Lighting/Rigging GridCorus Entertainment • Studio and Architectural Pipe Grid

CTV (Various Studios) • Motorized Grid System, Lighting Grids and Lighting Grid Reconfiguration

Track & Rigging Systems

Technicolour Production Services • Counterweight 3D Screen DropOntario College of Arts • Black Box Track System

Heritage Park Alliance Church • Full Stage Rigging & Track System