Rigging Certification -- Loader Purdue University Theatre April 8, 2006 Purdue University Theatre 9/18/2018

Introduction Counter Wait? How to knot hurt yourself and others Principles of counterweight systems How to knot hurt yourself and others Safe working practices on the weight rail Weight loading techniques and methods Help! I’m tied up! Common rope types and uses Common knots and uses Purdue University Theatre 9/18/2018

Counterweight systems Used to enable scenery to come from and disappear above the stage Simple in concept: a system of ropes and pipes is used to move scenery up and down (known as “flying in” or “flying out”) Weight is used offstage to balance the weight of scenery onstage Purdue University Theatre 9/18/2018

Counterweight systems Two common types of counterweight systems Single-purchase Double-purchase Purdue University Theatre 9/18/2018

Single-Purchase Counterweight System Parts of a single-purchase lineset system: Head block for lift and hand lines Loft blocks (mule blocks as needed) Wire-rope lift lines Batten Hand line (purchase line) Counterweight arbor Lock rail Tension block T-bar guide rails Loading bridge Single-purchase systems are used in a 1:1 ratio: for every foot of movement on stage, the purchase/hand line will move one foot; for every pound of weight loaded on the batten, one pound of weight will be loaded on the arbor. Purdue University Theatre 9/18/2018

Double-Purchase Counterweight System Parts of a single-purchase lineset system: Head block for lift and hand lines Loft blocks (mule blocks as needed) Wire-rope lift lines Batten Hand line (purchase line) Counterweight arbor Lock rail Tension block T-bar guide rails Loading bridge Arbor blocks Hand line tie-off Hand line and lift line tie-off Double-purchase counterweight systems utilize compound rigging for both the hand lines and the lift lines; the batten will travel 2’ for every 1’ of arbor travel, and for every 1 pound of load, 2 pounds of counterweight are required. Purdue University Theatre 9/18/2018

Counterweight systems Because single-purchase systems operate in a 1:1 ratio, they must be able to travel the full distance of travel required of the batten (i.e. for a batten to descend 65' from the grid, the arbor must ascend 65' toward the grid) Because double-purchase systems operate on a 2:1 ratio, they only need to travel half as far; however, they need to stack twice as much counterweight, which means taller (and harder to load) arbors Purdue University Theatre 9/18/2018

Counterweight systems The Hansen Theatre employs a single-purchase counterweight system 34 counterweight linesets 2 counterweight tab pipe linesets (running US-DS) 56' battens maximum live load 1450# 5 lift lines with self-levelers T-track guided steel arbors maximum load 1850# 2 counterweight (brick) sizes: 1" (1/2 brick), 14# 2" (full brick), 28# Note that the maximum allowable load on the batten is less than the maximum allowable load on the arbor; because of this, it is never possible for a safely loaded lineset to be too heavy to be counterweighted properly. Purdue University Theatre 9/18/2018

Lift lines and Hand lines Wire rope lines connecting the batten to the arbor Hand lines Provide method of operation of the lineset The hand line is essentially unrelated to the counterbalancing of the weight on stage A counterweight system can “counterweight” a batten without a hand line Changing the hand lines, for example, can be done with a load on the batten. This is, of course, not safe practice, and not advised. Purdue University Theatre 9/18/2018

The Lock Rail The lock (locking) rail supports a series of rope locks, one for each hand line The lock is intended to keep a safely balanced batten in position The lock is never intended to hold a heavily unbalanced (“out-of-weight”) load while loading or unloading Purdue University Theatre 9/18/2018

Rope Locks Purdue University Theatre 9/18/2018 Consists of a pair of jaws and a lever arm. The arm has a cam, which presses against the onstage jaw, causing it to pinch the rope between both jaws. A steel ring (through which the hand line is threaded) slips over the lever when it is up (or locked). The ring locks the lever closed and keeps it from falling open. A properly adjusted rope lock will be “self-locking”; in other words, when it is raised 2 degrees above horizontal, it will stay in position. The pressure of the jaws is easily adjusted by means of a thumbscrew on the back of the lock. Purdue University Theatre 9/18/2018

The Arbor Purdue University Theatre 9/18/2018 The arbor is the rack that holds the counterweights Consists of a top plate, a bottom plate, a back plate, 2 guide shoes, 2 steel guide rods ¾" in diameter, a series of steel spreader plates, and a locking plate Purdue University Theatre 9/18/2018

The Arbor The guide rods keep the counterweights in place The spreader plates prevent the guide rods from spreading apart should the arbor smash into the top or bottom stops; if the guide rods were to spread, counterweights could fall out Spreader plates should be distributed every 2' (12 bricks) The lock plate prevent counterweights from falling out in the event of a crash, and should be locked down above the topmost counterweight The arbor is the rack that holds the counterweights Consists of a top plate, a bottom plate, a back plate, 2 guide shoes, 2 steel guide rods ¾" in diameter, a series of steel spreader plates, and a locking plate Purdue University Theatre 9/18/2018

Vocabulary Pipe weight In-weight Out-of-weight Pipe Heavy Arbor Heavy The weight necessary to counterbalance the weight of the batten and the lift lines Pipe weight on each arbor is painted yellow, and should never removed from the arbor In-weight Refers to a state of balance on a lineset Out-of-weight Refers to a state of imbalance on a lineset Pipe Heavy Refers to an out-of-weight lineset which is heavier on stage (at the batten) Arbor Heavy Refers to an out-of-weight lineset which is heavier at the arbor Flying in (coming in) The movement of a lineset or scenery down toward the stage Flying out (going out) The movement of a lineset or scenery up away from the stage Heads Announcement used to indicate an uncontrolled, falling item Mention pipe weight on the tab pipes. Purdue University Theatre 9/18/2018

The Loading Gallery The Hansen Theatre has two loading galleries, at approximately 50' and 60' above the stage When accessing the galleries (or any overhead position), remove all loose articles including hardware, tools, coins, wallets, or other items that might fall from your person All of the galleries, with the exception of the upper loading gallery, are accessible via standard stairwell Purdue University Theatre 9/18/2018

The Loading Gallery Only authorized personnel are permitted on the galleries Unless wearing a fall-arrest harness and secured to the gallery, the guard chains must remain in place Never load or unload weight without being specifically directed to by the fly operator Always use proper calls when loading and unloading weight Always stack weights on the onstage side of the gallery Never stack weights higher than the kick plate on the gallery floor Purdue University Theatre 9/18/2018

Cadence (or calls) When loading weight: When unloading weight: “Fly rail: loading 3 bricks, lineset 13.” When unloading weight: “Fly rail: unloading 4 bricks, lineset 3.” When weight is loaded: “Fly rail: lineset 12 at seven bricks above pipe weight.” When weight is unloaded: “Fly rail: lineset 7 at pipe weight.” or, “Fly rail: lineset 7 now at 3 bricks above pipe weight.” Purdue University Theatre 9/18/2018

Proper Loading Procedure Announce commencement of loading to fly rail Loosen lock plate Slide spreader plates and lock plate up on the arbor and out of the way (secure with a metal spring clip) Firmly grasp brick with two hands, one on each side Always keep two hands on the brick! Slide brick onto arbor and around rear guide bar Lift near end of brick up and over to clear front guide bar; lower around front guide bar Continue in this manner until proscribed number of bricks is loaded Slide a spreader plate down onto the stack after every 12th brick Slide spreader plates and lock plate down Tighten lock plate Announce completion of loading to fly rail Purdue University Theatre 9/18/2018

Proper Unloading Procedure Announce commencement of unloading to fly rail Loosen lock plate Slide spreader plates and lock plate up on the arbor and out of the way (secure with a metal spring clip) Firmly grasp brick with two hands, one on each side Always keep two hands on the brick! Lift near end of brick up and over to clear front guide bar; lower to rest on stack to the side of front guide bar Slide brick from rear guide bar and off the arbor Stack brick on the gallery (on the onstage side, never higher than the kick plate) Continue in this manner until proscribed number of bricks is unloaded Slide spreader plates and lock plate down Tighten lock plate Announce completion of unloading to fly rail Purdue University Theatre 9/18/2018

Common Ropes Manila (natural fiber) Best natural fiber rope Because it is a natural fiber, it ages and loses strength Internal rotting Drying and dampening from atmosphere Stretching over time Purdue University Theatre 9/18/2018

Common Ropes Three-strand twist (polyester, Multiline II) 2 times stronger than similar-sized manila Synthetic fiber is not susceptible to atmospheric aging Less likely to stretch than manila Because it is twisted like manila, any fiber breakage reduces the strength of the rope Purdue University Theatre 9/18/2018

Common Ropes Parallel Core (polyester, Stage-Set X) 3½ times stronger than similarly-sized manila Continuous polyester fibers surrounded by a polyester jacket 95% of strength is in the core; minor damage to jacket does not effect strength Synthetic fiber is not susceptible to atmospheric aging Nearly limitless lifespan Purdue University Theatre 9/18/2018

Common Ropes Breaking Strengths for Manila, 3-strand twist, and parallel core Purdue University Theatre 9/18/2018

Common Knots Effects of knotting Knotting a rope produces bends and shear stresses, and alters the geometric cross-section of the rope Knots thereby reduce the breaking strength Ropes will typically fail next to the knot Two common (and preferred) theatrical knots Clove hitch (used for tying to a rigid object, like a batten) 75% efficient (reduces breaking strength by 25%) Bowline (used for creating a loop in a rope 60% efficient (reduces breaking strength by 35%) Purdue University Theatre 9/18/2018