1. Counterweight Fly Systems

2. What is a Counterweight Fly System?
A system of raising and lowering scenery and lights using a set of pipes, cables, ropes, pulleys and weights.
Allows for vertical storage above the stage in the flyhouse.
Also allows for utility work
bringing electrics in to hang/remove lights
Made from a series of line sets is one system of a pipe, all of the cables, pulleys (blocks) and rope

3. Where is all this stuff? In the fly house.
The fly house is the space above the stage where scenery, curtains and electrics are stored when not in use
Fly house is masked by what?

4. Line Sets
One set of counterweight components: batten, lift lines, blocks, arbor, purchase line, stage weights, etc.
The Concert Hall has 33 Line Sets
25 Manual and 8 Motorized
Which are motorized?
Electrics
Concert Ceilings
Fire Curtain (Separate system)

5. Parts of a Line Set on a Counterweight Fly System
GET OUT YOUR DIAGRAM

6. Loft Block Grid Lift Line (Aircraft Cable) Loading Gallery Trim Chain
Multi-Grooved Head Block
Grid
Lift Line
(Aircraft Cable)
Loading Gallery
Trim Chain
Arbor
Batten
Attachment Line
T-Track
Purchase Line
Load
Locking Rail
Rope Lock
Lock Ring
Tension Pulley

7. Multi-Grooved
Head Block
Loft Block
Arbor Rod
T-Track Guide
Collar locks
Arbor Backbone
Stageweight, Pig, Brick
Lock Ring
Rope Lock
Tension Pulley

8. What are the pipes called?
The pipe on a line set is called a batten:
our battens are 63’long
industry standard Schedule 40 Black Pipe
The proscenium opening is 50’-0” wide
Why are the battens 13’ longer than the proscenium opening?

9. Before You Move a Batten
Call the following EVERY time you use the system, BEFORE unlocking the line set (except during performance):
Heads up - Get their attention!
Line set # - What are you moving?
Coming in/going out – Which way?
Location (US, DS, CS) – Where?
Wait to hear “Thank You” – Confirm they heard you.

10. To Move a Batten After calling the batten:
Remove the lock ring and rest it on the rope lock.
Unlock the rope lock (pull the lever toward you).
Locate the batten you’re moving and check to make sure there’s nothing obstructing it’s path.
Pull where the purchase line is closest to you to bring the batten in, pull where the purchase line is further from you to take the batten out.
Lock the batten when done (don’t forget the ring).

11. Types of battens Single pipe batten (Type I)-Most of our battens
One pipe suspended by lift lines (7 on our stage)
Truss Batten
Our only truss battens are our Concert Ceilings.
Tri-Batten
Aka. Electrics

12. Grid
An open floor made of a “grid” of iron high over the stage (54ft on our stage)
loft blocks are mounted here are carry a lift line across the stage.

13. What’s a Block?
A pulley mounted in a fixed position (like the engine block on a car).

14. Motorized Line Sets A dead-lift system
electric winches & motor lift heavy loads
4 Electrics & 3 Concert Ceilings are motorized
Controlled by motor control panel OR
Pendant (remote) - allows for 4 preset targets
Why not motorize all battens?
Slow, dangerous, and costly.

15. Types of Counterweight Systems
Single Purchase
L.T.P.A.C. Concert Hall
1:1 ratio for travel and weight
1lb. of load on the batten = 1lb. of weight on the arbor
batten travels 1’ = arbor travels 1’
Purchase line tied to both ends of the arbor

16. Types of Counterweight Systems
Double Purchase
UTPAC Bass Concert Hall
1:2 ratio for travel and weight
1lb. of load on the batten = 2lbs. of weight on the arbor
2’ of travel for the batten = 1’ of travel for the arbor
Increased Mechanical Advantage
More room for and risk associate with error.

17. Stageweights, Bricks, or Pigs
Made of pig iron or lead.
We have three sizes of stageweights:
10 lb
20 lb
40 lb

18. Spreader Plates Primary purpose: prevents arbor rods from bending
like a toggle
commonly misunderstood
Place spreader plates:
on top of the brick stack
every 2 feet

19. Muled Sets Used when architecture blocks safe arbor placement
Lift lines are run twice to allow the arbor to be placed in a different location from the batten.
Adds significant friction
Requires special attention to potential problems

20. To Rig Scenery to a Batten
Bring the batten to the deck (stage floor).
Attach load to the batten (use rated hardware).
Use shipping info or other educated estimates to determine the weight of the load.
Crew on loading gallery adds arbor weight.
Check the lineset for balance.
No movement when the load and arbor are level.
Repeat steps 4 & 5 until balance is achieved.
Reverse method to remove scenery.

21. Counterweight Safety (From Safety Memo)
Quite when battens are moving.
Only Bartosh/Chill/Crew Heads talk to loading crew.
Complete silence during loading of arbors.
Line sets must always be left balanced and locked.
Make sure rail is lit.
Rope locks will not hold out of weight line sets.
Remain in control: at least one hand on an unlock purchase line.
Safer to be slightly arbor heavy.
Raise and lower battens slowly, and do not force battens.
Make sure SL is clear.
Yell “HEADS!” In an emergency.
Always attach loads first.
Always remove weight first.