ng . Glerum 5 t Jay O Ig }hand took Stage RStage Rigging Handbook Second Edition Jay O. Glerum Southern Illinois University Press Carbondale and EdwardsvilleUSARTY ag \v Copyright © 1987, 1997 by Jay O. Glerum All rights reserved. First edition 1987 Second edition 1997 Printed in the United States of America 00 99 98 97 43 21 Library of Congress Cataloging-in-Publication Data Glerum, Jay O. Stage ti p. cm. Includes bibliographical references. 4, Stage machinery—Handbooks, manuals, etc. 2. Stage management—Handbooks, manuals, etc. 3. Theaters—Safety measures—Handbooks, manuals, etc. 4. Theaters—Stage-setling and scenery—Handbooks, manuals, etc. |. Title. PN2091.M3G54 1997 792' .025—dc20 96-7589 ISBN 0-8093-1744-3 CIP. ing handbook / Jay ©. Glerum.—2d ed. ‘The paper used in this publication meets the minimum requirements of American National Standard for Information Sciences—Permanence of Paper for Printed Library Materials, ANSI 239.48-1984, ©Part 1 1.01 1.02 1.03 1.04 1.05 Contents Preface to the Second Edition xiii Preface to the First Edition xv Symbols and Abbreviations xvii Loads and Reactions 1 The4K’s 1 Knowing the Rigging System 2 A. Load and Force 2 B. Static Equilibrium 3 Supporting a Load 3 ‘The Engineer and the Rigger 3 Seat-of-the-Pants Experience 4 Free Body Diagram 4 Summation of Forces 5 Moment of Force 7 Examples 9 onmoomp> Continuous Beams 13 Summation of Forces 14 A. Resultant Force 14 B. The Law of Sines 15 C. Table of Multipliers for Resultant Forces. 16 D. Vectors 18 Bridle Analysis 18 A. Bridle Length Calculation 20 B. Vertical and Horizontal Forces 21 G. Bridle Tension 231.06 Part 2 2.01 2.02 2.03 2.04 Vector Analysis 24 Hanging Points of Different Heights 25 Ratio of Horizontal to Vertical Distance 28 Allowable Loads 29 zomnmosg The Effect of Bridles on Hanging Points 29 Strength of Materials 30 ‘Types of Applied Forces 31 Stress, Strain, and Hooke's Law 32 Yield Point and Elasticity 34 Ultimate Breaking Point 36 Torsion 36 Unpredictable Forces 36 Design Factor of Components, Working Load Limit 37 zomnmosog> Determining the Design Factor 38 Block and Tackle Rigging 41 Introduction 41 Anatomy of a Block and Tackle System 42 A. Wooden Blocks 43 B. Metal Blocks 44 C. Other Types of Blocks 44 Load Distribution on a Block 44 A. Static Load 44 B. Dynamic Load 46 Mechanical Advantage 48 ‘A. Apparent Mechanical Advantage 48 B. Actual Mechanical Advantage 49 ©. Calculating Lead Line Pull 51 D. Mechanical Advantage of Common Systems 52 vi2.05 2.06 2.07 Part 3 3.01 3.02 3.03 E. Calculating the Total Load on the System 56 F Rope and Sheave Wear 56 G. Mechanical Advantage of Complex Systems 57 Lacing and Reeving of Blocks 58 Inspecting a Block and Tackle System 61 Using a Block and Tackle System 62 A, User's Checklist 62 B. Attaching 62 C. Operating 63 D. Storing 63 Hemp Rigging 65 Introduction 65 The Hemp Systems 65 A. Single-Line System 65 B. Multiple-Line System 66 C. Sandbag and Arbor Attachment as Counterweight 67 The Rope 68 Considerations of Rigging Rope 68 Types of Natural-Fiber Rope 70 Synthetic-Fiber Rope 71 Tensile Strength or Breaking Strength 73 Strength and Allowable Working Load of Rope 73 Effects of Knotting 75 Care of Rope 76 rommoop> Indications of Wear 79 Testing a Rope 81 S Bo'sun's Chair 81 K. Selecting the Right Rope for the Job 82 vii3.04 3.05 3.06 3.07 3.08 3.09 Blocks 82 A. Loads 85 B. Head Blocks 87 C. Loft Blocks 88 D. Spot Blocks 88 E. Mule Blocks 89 F. Idler Pulleys 90 G H Sag Bars 90 Snatch Blocks 91 Pin Rail 92 A. Fixed Pin Rail 93 B. Loose Pin Rail 93 C. Single Pin Rail 93 D. Double Pin Rail 93 E. Pins 93 F Tying Off 95 Sandbags and Arbors 98 A. Allaching Sandbags and Arbors with a Sunday 98 B. Attaching Sandbags and Arbors with a Trim Clamp 99 dack Line 102 Spot Line Rigging 102 A. Positioning Loft Block 103 Positioning Head Blocks 103 Fleet Angle 103 . Aligning Blocks 104 moog Running Rope 105 F. Attaching Weight to Rope 105 Operation of Hemp Rigging 105 A, Safety Inspecting All Components 107 vill3.10 3.11 3.12 Part 4 4.01 4.02 4.03 4.04 4.05 4.06 4.07 Untying a Line Set 107 Attaching Loads 108 Removing Loads 108 Trim Marks 109 Lashing with Small Stuff 109 Retrimming 111 rommoonp Coiling and Dressing 111 |, Showtime Operation 111 Operation Summary 112 Safety-Inspection Summary 112 Historical Summary 112 Counterweight Rigging 114 Introduction 114 Single-Purchase Counterweight System 115 Double-Purchase Counterweight System 116 Miscellaneous Hardware 117 Wire Rope 118 Properties of Wire Rope for Stage Rigging 118 Construction of Wire Rope 121 Grades of Wire Rope 122 Attaching to Batten and Arbor 125 moon, . Indications of Wear 131 Wire-Rope Blocks 133 A. Material 133 B. Sizing 134 C. Head Blocks 135 D. Tension Block 135 Lock Rail 136 A. Lock 136 ix4.08 4.09 410 44 4.12 413 4a4 B. Lock Adjustment 138 C. Load Limit and Identification 138 Arbor 139 A. Guide Systems 139 B. Pipe Weight 140 Hand Line 142 Loading Bridge 143 A. Storing Weights 143 B. Loading and Unloading Weights 144 C. Identifying Load Limits and Weights 144 Loading and Unloading Using a Loading Bridge 146 A. Crew Responsibilities 146 B. Communications 155 C. Runaway Set 155 D. Loading 155 E. Unloading 156 Loading and Unloading without a Loading Bridge 156 A, Partial Loads 156 B. Unbalanced Large Loads 156 Showtime Operation 161 Label the Lock Rail 161 Use Tim Marks 161 Knuckle Buster 163 Preshow Testing 163 Cuing 163 Special Counterweight Rigging Problems 164 A. Lighting Battens 164 B. Variable Load 164 moo 9 > C. Increasing the Counterweight Capacity 16645 4.16 Part 5 5.01 5.02 5.03 5.04 5.05 5.06 5.07 5.08 5.09 Operation Summary 167 Safety-Inspection Summary 167 Motorized Rigging 169 Introduction 169 Systems Descriptions 171 A. Motorized Counterweight Systems 171 B. Straight Winch 172 C. Line-Shaft System 173 Motor Types 176 A. AC Electric Motor 176 B. DC Electric Motor 176 C. Hydraulic Motor 176 Electric Winch Components 179 Motor 179 Gear Reducer 179 Brakes 179 op > Drum 180 Controls 180 mmo Rigging Components 184 Hydraulic Winch Components 184 Hand Winch 184 Operation of Motorized Rigging 186 A. Safety Inspect All Components 187 B. System Capacity 187 C. Loading and Unloading 187 D. Showtime Operation 188 Operation Summary 188 Safety-Inspection Summary 188 xiPart 6 6.01 6.02 6.03 6.04 6.05 6.06 6.07 Cutting and Knotting Rope, Attaching Loads, Special Problems 190 Fiber Rope 190 A. Cutting 190 B. Knots 192 Wire Rope 196 A. Cutting 196 B. Unreeling and Uneoiling 197 C. Terminating 197 Bolts 207 Attaching Loads 209 Curtains 209 Drops 210 Vertical Framed Scenery 211 Horizontal Framed Scenery 213 Point Loads 215 Special Problems 217 moog > Breasting 217 Tipping 217 Guiding 218 Dead Hanging 218 Flying People 218 moog > Recordkeeping 220 A. Rail Log 224 B, Inspection and Maintenance Log 221 Operator Training 221 Glossary 225 Selected Bibliography 229 xiSTAGECRAFT Succinct and jargon free, Stage Rigging Handbook remains the only book in any language that covers the design, operation, and maintenance of stage rigging equipment. It is written in an at-a-glance outline form, yet contains in-depth information available nowhere else. This second edition includes two new parts: the first, an expanded discussion of the forces. and loads on stage rigging components and the structure supporting them; the second, an examination of block and tackle rigging. The remaining four parts contain numerous revisions. Explaining his purpose, Jay O. Glerum points out that four main principles make up the core of this book: know the rigging system; know that it is in safe working order; know how to use it; keep your concentration. Glerum applies these principles to all of the major types of stage rigging systems, including block and tackle, hemp, counterweight, and motorized. He describes each type of rigging, then thoroughly reviews the operating procedures and ways of inspecting existing systems. In his Dramatics review of the first edition of this book, Steve Nelson wrote: “It should be noted that this is definitely a reference book. It's meant to be skimmed first and then attacked in chunks according to your needs. It is organized in outline format, with para- graphs of text on each item. Black and white photos, line drawings, and tables illustrate the text. ... What Stage Rigging Handbook will do is clearly explain the basics of how to maintain your rigging system and operate it safely. It can also be a ready reference and friend when rigging a show. This is a book to always keep handy in a cubby hole at the end of your pinrail. Be safe. Don't guess.” Derek Hunt agreed in his Theatre Design and Technology review: “With the informa- tion that it contains, Stage Rigging Handbook should become a standard text for advanced technical students and all individuals concerned with the safe and proper maintenance and operation of stage rigging systems.” Jay O. Glerum regularly teaches classes on stage rigging throughout the United States, Canada, and Europe. He currently chairs the Rigging and Stage Machinery Standards Committee of the United States Institute for Theatre Technology. A fellow of the Institute, he is president of Jay O. Glerum & Associates, Inc., a firm specializing in consulting for the entertainment industry. Southern Illinois University Press P.O. Box 3697 Carbondale, IL 62902-3697 Piano Unt Sats of ner INTO TSBN 0-8093-1744-3 ISB-N~@-8093-1744-3 1 ee $37.50 Wut qt el oases 9 "780809"317448) THEATREBOOKS LTD