If you want to pull off a safe and visually stunning performance, updating your rigging system is a must. As the backbone of your set, lighting and audio designs, it’s important to know when your equipment no longer meets your production needs. Failing to spot the warning signs could result in hazardous disasters that put your audience, crew and performers at risk. This article breaks down seven common signs that your rigging equipment needs an upgrade.
Why Regular Rigging System Updates Matter
Even if you’re operating a newer system, wear and tear is inevitable. Mechanical fatigue and stress from heavy loads, dynamic set changes and multiple productions can add up.
Industry standards also require regular rigging upgrades as building codes and safety regulations change. What was once compliant a few years ago may be outdated when compared to the latest ESTA and ANSI guidelines. Auditing and inspecting your rigging routinely helps you to spot minor issues before they develop into larger problems.
#1: Visible Wear on Cables, Lines and Hardware
Fraying cables, corroded connection points and aging shackles are sure signs that your theatre rigging is reaching its limit. It may also suggest the internal structural integrity of your theatre’s equipment is even more compromised than you realize. Waiting to address visible wear not only increases the risk of failure during production, but it also puts your performers and crew in danger if elevated components fall.
#2: Frequent Adjustments or Mechanical Issues
A quality rigging system shouldn’t require constant recalibration to execute simple movements. Improperly adjusted stage rigging can create inconsistencies during production. That could present as drifting scenery, cord slack, increased component wear and more frequent repairs. That poses a problem for rehearsal and makes it hard to sync up cues to complete transitions safely. As your rigging’s integrity decreases, the space for error widens, which puts people in danger and your liability on the line.
#3: Jerky Fly System Movement
If your production includes lifts, descents and horizontal transitions, you need a reliable fly system to control curtains, drapes, screens and scenery.
Inconsistent fly system movements could suggest:
- Worn or damaged wires
- Flat spots in sheaves
- Misaligned counterweight arbors
- Lack of lubrication or debris buildup
- Poorly calibrated control systems
#4: Outdated Motorized Technology
Some older manual rigging setups were created with mechanical simplicity in mind, but lack the necessary safety features required of today’s systems. Industry standards and building codes demand automatic safety stop capabilities, so if your rigging lacks those components, it’s time to upgrade. Load monitoring is another important aspect of maintaining structural integrity. Overloading an older system that doesn’t offer real-time monitoring can make it difficult to execute quick adjustments.
#5: Failed Safety Inspections
Whether you’re conducting in-house inspections or bringing in professionals, if you identify these recurring issues, a rigging update is needed:
- Connection point failures
- Movement in anchor points
- Cracked or deformed loft and head blocks
- Misaligned arbor tracks
- Control system reinitializations
- Emergency stop system failure
- Software error codes
- Increased inspection variances
#6: Excessive Noise or Vibrations
Grinding, squealing and clunking noises are common signs that you need to renovate your rigging. They may indicate metal-on-metal, worn bearing surfaces and inadequate lubrication that can accelerate the rate of wear. Banging sounds could suggest impacts from rope locks and attachment points, especially if they’re moving under a heavy load. If you notice vibrations in your theatre rigging, it’s likely not absorbing and dissipating energy properly, either.
#7: Difficulty Executing Complex Productions
Modern set designs often feature complex movements and extensive coordination between scenery, lighting and sound elements. Large-scale productions and touring performances are more technically demanding than some dated rigging systems – particularly manually-operated ones – can handle. If your equipment can handle high load capacities and quick movements, you may need to consider an upgrade to accommodate more diverse performances.
Update Your Rigging with Tiffin Scenic Studios
Whether you’re working in a historic venue or an outdated system, Tiffin Scenic Studios can retrofit your performance space with updated rigging to optimize your productions. We offer a variety of design, installation and inspection services so you can make the most of your investment. Check out our portfolio and contact us to schedule a consultation.