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Counterweight Fly Systems

Counterweight Fly Systems. Technical Theatre Mr. Bartosh. What is a Counterweight 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 “heavens”

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Counterweight Fly Systems

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  1. Counterweight Fly Systems Technical Theatre Mr. Bartosh

  2. What is a Counterweight 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 “heavens” • Also allows for utility work (bringing electrics in to hang/remove lights)

  3. Where do the pipes go? • Into 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. What are the pipes called? • A line set is one system of a pipe, all of the cables, pulleys (blocks) and rope • The pipe attached to a line set is called a batten • On the Concert Hall stage, our battens are 63’-0” long • Our battens are industry standard 1-½” Schedule 40 Black Pipe • The proscenium opening is 50’-0” wide • Why are the battens 13’ longer than the proscenium opening?

  5. Types of battens • Single pipe batten • One pipe suspended by lift lines (7 on our stage) • Truss Batten • 2 pipes joined together by steel connector bars • Looks like a ladder on it’s side • Advantage? • Holds more weight (and has a bigger arbor) • Tri-Batten • 2 pipes joined together and tipped at an angle, joined to a 3rd pipe above (with a raceway for dimmer circuits) • Used for “electrics” • Battens used for lighting

  6. Grid • An open floor made of a “grid” of iron high over the stage (54ft on our stage) • Perpendicular to the iron, loft blocks are attached to carry a lift line towards the stage floor. • The open spaces in the grid floor are designed to allow additional pulleys and lines for special spot lines.

  7. What’s a Block? • Loft blocks (or any block) is a pulley that’s mounted in a fixed position. • The “wheel” that rotates as the cable runs over it is called a Sheave

  8. Fire Curtain • Primary purpose of the fire curtain: • To isolate the fire and save lives • Always located most downstage • Three ways to bring in: • Motor control (allows for raising and lowering) • Emergency pull handles (one way only) • Fusible links (activated by heat, one way only)

  9. Pin Rails • Used to tie off pick lines (spot lines) • Spot lines are placed where lightweight loads need to be lifted • A large steel pipe with holes along it where wooden Belaying Pins can be inserted, and ropes tied off • Usually located on or near the fly rail

  10. Line Sets • One complete set of counterweight components (batten, lift lines, blocks, arbor, purchase line, stage weights) • The Concert Hall has 23 Line Sets • 22 Manual Line Sets • 1 Motorized • Which is motorized?

  11. Motorized Line Sets • A type of dead-lift system that employs electric winches designed for the purpose of lifting scenery • Controlled by a motor control panel stage right, near the Stage Manager’s Panel • Winch: A hand-cranked or motorized drum rigged with cable used to move scenery

  12. Types of Counterweight Systems • Single Purchase • L.T.P.A.C. Concert Hall • 1:1 ratio for both travel and weight • 1 pound added to the batten means 1 pound must be added to the arbor • 1 foot of travel for the batten means the arbor will travel 1 foot • What does this mean the length of the T-Tracks must be? • Purchase line is tied to the top & bottom of the arbor

  13. Types of Counterweight Systems • Double Purchase • UTPAC Bass Concert Hall • 1:2 ratio for travel and weight • 1 pound of weight added to the batten means 2 pounds of weight must be added to the arbor • 2 feet of travel on the batten means the arbor will travel 1 foot • Provides a mechanical advantage • Arbor tracks only have to be ½ as long as the batten travels • Purchase line is tied to the head-block girder and anchored to the floor

  14. Stageweights, Bricks or Pigs • Made of pig iron or lead • We have three sizes of stageweights: • 15 lb • 20 lb • 40 lb

  15. Trim • Trim is the height of something above the deck (stage floor) • In-Trim is the position of scenery as it should be when in use • Out-Trim is the position of scenery as it should be when not in use

  16. Spreader Plates • A commonly misunderstood part of the arbor • Primary purpose is to prevent the arbor rods from bending • The spreader plates should be at the top of the brick stack on the arbor, and leave one behind every 2 feet in the stack

  17. Before You Move a Batten In a loud, clear and serious tone call the following EVERY time a batten is about to move (except during performance) • Heads up • Line set # • Coming in/going out • Location (US, DS, CS) • Make sure people on stage heard you with their response “thank you”

  18. To Move a Batten After calling the batten: • Remove the lock ring and set it quietly on the rope lock • Unlock the rope lock by pulling the red lever away from the purchase line • Locate the batten you’re moving and check to make sure there’s nothing obstructing it’s path to it’s destination • Pull the purchase line closer to you to make the batten come in, pull the purchase line away from you to make the batten go out. • Lock the batten off when done. • Report any out of weight situations (the batten moves without you pulling the line) to Mr. Bartosh

  19. To Rig Scenery to a Batten • Bring the batten all the way in to the deck • Attach the scenery to the batten using only rated stage hardware • Use shipping information, or good estimation to determine the weight of the scenery • Have a loading crew at the loading gallery add that amount of weight to the arbor • Check the lineset for balance • Repeat steps 4 & 5 until completely balanced • Use this method in reverse to remove scenery from a batten

  20. Counterweight Safety (From Safety Memo) • Complete silence when battens are moving or loading of arbors • Make sure rail is lit • Remain in control at all times, at least one hand on purchase line when unlocked • Raise and lower battens slowly • Do not force battens • Do not bang the grid or deck • Yell “HEADS!” In an emergency • Do not sit on fly rail • Only Mr. Bartosh or crew head talk to loading crew • Line sets must always be left balanced and locked • Rope locks will not hold out of weight line sets • Safer to be slightly arbor heavy than batten heavy • Make sure SL is clear before loading operations • Always attach loads first, then weight the arbor • Remove weight first, then remove loads

  21. Parts of a Single-Purchase Counterweight Fly System

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

  23. Loft Block Multi-Grooved Head Block Grid Arbor Lift Line (Aircraft Cable) Batten Stageweight, Pig or Brick Purchase Line Rope Lock Tension Pulley

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

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