Helmets - Protecting your noggin at a fraction of the price of brain surgery

Typical 4-point suspension
ANSI type I protection

Traditional hard-hats used by construction workers aren't much more than a skid lid to keep your hair on your scalp.  That isn't to say it isn't a good thing, especially for us 'folically challenged' folks.  However, when you flip one of these over and study the inside you suddenly realize that the shock absorption mechanism is anything more than a few nylon ribbons that are supposed to 'predictably' fail and take some of the wham! out of the slam!-bam! of a falling object.

There is no joy in scraping your skull along the bottom of a low-lying air duct, sprinkler pipe, or cross-bracing steel.  The pain is excruciating, and dripping blood from the catwalk is poor manners.

A few years ago, well actually ALOT of years ago, helmet manufacturers realized that adding a layer of crushable foam (typically styrofoam) to the inside of a helmet would increase the energy dissipation significantly.  We first saw this technology applied to motorcycle and auto racing helmets, and then to bicycle helmets.  It eventually made its way into rock climbing helmets, and from there into the world of construction helmets.

KASK Super Plasma Helmet interior view - ANSI type II protection.
Note the two layers of padding:  both Styrofoam and a fabric covered foam cushion.

Conventional hard hat with 4-point chin strap

Although you can buy accessory chin straps for cheap hard-hats, the chin straps don't always stay attached, they are difficult to find and buy, and they frequently cost more than the hard-hat itself.  In the theatre and show production industry we seem to spend a lot of time either bent over (hold the jokes please . . .) or working at height.  Both of these work situations demand that your PPE remain secured to your person.  You don't want you hard-hat falling into the scenery that you are painting, and you don't want it to fall from the truss or catwalk you are working upon.  Either way, when your hard-hat departs your head you are exposing yourself to injury AND you may be exposing the inattentive and unwilling participant below you to the full impact of your helmet on their head.  Hopefully, they are wearing some head protection, too!

Single chin strap accessory

So, if you drop you helmet to the stage floor below, will it damage it?  Yes, it will.  The next stop for that hard-hat is the dumpster.  You probably can't see the micro-fractures that impact set-up in the plastic, but I'd never trust the helmet to protect my brains again.  So, for a $5 big-box ANSI type I hard-hat, this is no big deal, but when you start wearing a $85-$150 ANSI type II hardhat, then protecting your investment (both your PPE and your brains) is a bit more of a concern.

KASK Super Plasma - ANSI type II protection

Myth:  Rock climbing helmets aren't OSHA compliant.  Any helmet that meets the ANSI/ISEA Z89.1-2009 or 2014 standard is acceptable.  It may not look like Bubba's typical construction site hard-hat, but if it meets the standard and is labelled as such, then it's legal.

So, what can yo do to keep a cool head and be stylin' on truss?  Get one of those really protective and 'I'm a professional' looking ANSI type II helmets and wear it!  The two most popular climbing helmets are the Petzl Verex Best and the KASK Super Plasma.  Bright colors are recommended.  If you need to black it out for a show (common for truss follow spotlight operators), just have your costume department sew-up a black spandex cover for it.

Bottom line:  Unless your want your brains to become Zombie food, protect them.  No replacement parts are currently available.

There is no shame in protecting your brain!

Staging Truss System Collapse Kills One, Injures 13

Nanning, China 2015-10-29 - China News reports that during the construction of the stage for an upcoming Jolin Tsai concert the ground supported stage truss system collapsed.  On worker was killed, and 13 other were injured.  On of the injured is in serious condition, while the others only suffered minor injuries.

Truss System Before the Collapse

The incident occurred around 5PM local time at the Guangxi Sports Center Arena.

After the collapse workers assess damage.

Deconstructing a tangled web of steel, aluminum, and stretched cables is a dangerous endeavor - stress in materials can create booby-traps due to spring loading and fractures in components that have not yet fully failed.  Hopefully, the workers doing this are planning their work carefully.

Also note that only three of the workers in the pictures are wearing hardhats.  It is unclear, but likely, that safety shoes are not worn in this construction environment.  Few workers appear to be wearing bright colored clothes, which makes it more difficult to spot staff and avoid collisions.  All of these factors can contribute to further injuries.

This is particularly relevant as this Blogger is scheduled to address the China Stage Design Exhibition in Beijing on November 26th-29th to discuss the development of an Entertainment Safety Initiative similar to the US lead Event Safety Guide developed by the Event Safety Alliance.

Update:  Two more pictures:

 

Stanky Thang - Be Gone!

Sometimes it just isn't practical to bring your hard-hat with you, yet borrowing one from the tool pool seems a bit, well, yechy might be the word.  You don't know where that thing has been, or who has been wearing it.  The sharing of hard hats can bring the unwanted transfer of lice, skin disease, viruses, and, well, general yechiness!

Be polite to yourself and your guests and clean your gear, particularly your spare gear.  Wipe them down with disposable alcohol wipes, wash them with hot water and anti-bacterial soap, and keep them up off of the floor where bugs won't climb into them and build webs or nests (shudder . . .).  Believe me, 'Buzz' doesn't want to feel the after-effects of Brylcreem Bob's 'doo gel on his chrome dome.  Replacing the brow sweat band once in awhile would be a good idea, too!

GKR Industries offers the Hardliner™ disposable sanitary hard hat liner. Simple to install, easy to dispose of.

More info here:  www.gkrindustries.com/HardLiner.aspx

You light up my life, er, ah, Hardhat!

Hard hats are great, but they don't offer a lot of options for attaching headlamps. We work in near darkness many places in the theatre, and holding a pen-light in your mouth for any length of time can result in drooling all-over yourself and the flashlight - not mention the yech factor of where it may have recently been.  The typical elastic band type headlamps that hobbyist wear won't stay-put because the elastic band will slip across the slick surface of the hardhat and fall off at the most inopportune time.  Securing your flashlight to your hardhat frees-up your hands for more productive work.

Streamlight Rubber Strap Mount on firefighter's helmet, and Streamlight Clip Mount (inset).

Streamlight, makers of industrial strength flashlights for fire and rescue teams has a good solution:  The Haz-Lo Helmet Lighting Kit.  In includes a clamp bracket so you can secure the flashlight to the helmet rigidly with a pivoting mount, a rubber helmet strap with holes you can thread the flashlight through, and a 3AA LED flashlight with a tail cap type switch.  The clamp bracket has a captive screw so you won't be loosing those tiny parts.

More info at:  www.streamlight.com/en-us/product/product.html?pid=283

A pair of these lights provides redundancy and doubles your work light to 240 lumens, each running 6-1/2 hours.  Remember:  It is still a good idea to safety cable the flashlight to your hard hat, and safety cable you hard hat to your gear belt.

Bucket Bails Break Bones

The ubiquitous plastic bucket - it shows-up unannounced, hangs around like an unwanted house-guest, and finally spills it guts and gets thrown in the trash.

Aside from the obvious bad rigging (you did see that, didn't you?), plastic buckets have a serious weak point:  The metal bail that forms the carrying handle.  This is nothing but a piece of bent steel wire that hooks into the plastic rim of the bucket.  Given sufficient (over)loading, the plastic bucket can deform and let-go of the bail (literally tearing the plastic), and/or the metal bail can bend and lose it's grip on the bucket.  Either way - this thing is going down.

We just love to over-stuff our carry-alls, and when you add-up the weight of hand-tools, nuts & bolts, drills, and all that other crud you forget to clean-out, the weight can become significant.  This wouldn't be such a big deal if you were just carrying this across the stage or shop, but there are times we forget logic and tie a rope on thee a try to hoist them up to elevated work locations.  Not such a good idea - What was once just going to fall  a few inches onto your foot now becomes a bomb falling from overhead - maybe 20 feet, maybe 50 feet, depending where you are going with it.  Either way, this can be deadly should the handle fail.

Safe lifting of materials is usually best accomplished when the lifting system encompasses the load, this places the load on the lifting device and not on the object being lifted.

The folks at The Circus Company (I guess circuses use these things to haul food and water for the animals) have a simple, yet effective solution:  Build a load-rated sling designed to fit those 5-gallon buckets we are so fond of.

These slings are rated for 200 Pounds and are inexpensive (relative to the cost of a new noggin').  The handle is constructed of reinforced Nylon, and has an extra layer across the hoist point.  It's pretty snazzy, too!

Don't be a doofus and drop your load  - secure it!

More info at: www.thecircuscompany.com

Fly the friendly skys . . .

Shackle Pin Safety

When working at height, even the smallest of dropped objects can become deadly projectiles.  Show riggers working in arenas and stadiums can sometimes be more than 100' above the floor, so even a shackle pin can achieve a terminal velocity that could penetrate a hard-hat.  Ty-Flot, maker of all things to do with securing your tools, has announced the availability of a safety lanyard for shackle screw-pins.  Set-up with a mini-pivoting joint in the cable, it allows the free rotation of the shackle pin for installations all-the-while keeping it safely attached to the shackle bow when disengaged.  The device quickly installs using one field crimp.

Ty-Flot LAN-SHKL-CR

 When used in conjunction with a safety lanyard attached to the worker, it can prevent dropped shackles while they are being installed / removed, too - just clip your lanyard onto the shackle lanyard.  Check out their Retractable Wrist Cuff Lanyard:

More information at www.Ty-Flot.com

Keeping Dents Out of Co-workers Noggins

Ty-Flot, makers of tool restraint lanyards, has introduced a new way to work with drop prevention equipped tools and tool belts.  The Quick-Switch system allows the use of a short lanyard that fits between the tool and the worker's wrist so that long floppy lanyards are eliminated.

Conventional lanyards that are tied-off to work belts and climbing harnesses must be long enough to facilitate using the tool at extreme reach positions.  These longer lanyards allow dropped tools to travel farther and pick-up more speed before they are restrained.  If the tool lanyard loops over a railing, it can swing back and strike a worker severely.

The Quick-Switch lanyard connection on the short lanyards allow tools to change hands, and be stored without presenting large loops to snag on protruding objects around the worker.

More info at: www.ty-flot.com

Don't Drop What You Are Doing - Get a Grip

Objects at Heights: Love Stinks But Gravity Hurts. 

Free Webinar • Duration: 60 minutes

With the exception of Chuck Norris, hurricanes, and halitosis, there’s little more dangerous than a plummeting object. Unfortunately, most tools don’t come with wings, so when you have a butter-finger type of day (and we’ve all had ‘em), the tools and equipment you rely on can quickly turn into plummeting little (or big) bombs of destruction. Aerial safety goes beyond your standard fall protection. In the past, objects at heights hazard-planning has been an afterthought – or not even a thought. Today, regulators and professionals acknowledge the serious, life-threatening risks of falling objects and are instilling rules to ensure proper precautions are followed in the workplace

This educational webinar will overview:

• Objects at Heights Safety and how it is part of Safety at Heights planning
• Awareness of the costs of dropped objects and other Objects at Heights hazards
• Best practices for Objects at Heights within the Hierarchy of Controls 

Seminar brought to you by: EHS Today (The Magazine for Environment, Health, and Safety Leaders) and Ergodyne Work Gear.

Register at: Love Stinks But Gravity Hurts

Chicago Area Theatre Experiences Roof Failure

Midway Theatre's roof partially collapsed Friday, March 23, 2012. The building is at 721 East State Street in Rockford, Illinois has been vacant since about 2003.  Fortunately, no one was in the building during the collapse.

“We talked with the property owner and we ordered him to get some immediate shoring on the remaining trusses and get us an engineering report on the temporary shoring so we know it is done properly,” building code official Seth Sommer said. “Then, he will be working toward a permanent solution.”

Photo courtesy of Rockford Fire Department

Downtown architect and River District Association President Gary Anderson said the building is a historic Rockford landmark. Opened in 1918 with its signature 90-foot clock tower and curved stone facade, it serves as the eastern architectural gateway to downtown Rockford.  It is a building the Rockford Historic Preservation Commission was able to save, Anderson said, and it is listed among the city’s officially designated historic landmarks.

Although it was used as a movie house for many years, it was transformed into a community theatre, served as home to the Rockford Symphony Orchestra, and used as office space and a TV production studio for a time.

Entering buildings that used to be, or might make a good production space is risky.  One of the first things most building owner's let-go is the roof's weather seal, and this can lead to rapid rotting and rusting of structural members and ceilings, particularly plaster ceilings. Other hazards in old building can include rotted flooring and stair wells, asbestos, and mold spores due to decaying fabrics, animal feces, and even animals.  A few minor holes into a building can allow pigeons, rats, and sometimes larger animals to infest the space, and that will accelerate the rate if decay.  Further dangers include blocked exit routes, so should an entry path become blocked, there may not be another way out.

Old buildings can be wonderful treasures to restore, and can bring economic revitalization to downtown areas, but until they have been inspected by professionals and the necessary steps taken to shore-up structural elements, seal roofs, and mitigate health hazards, don't go poking around in them.

Things that go Bump in the Dark

Boom-Boom, Out Go The Lights! (Stray Cats covering Pat Travers covering Little Walter)  Well, that's what happens when you bonk your head really hard (yet another reason to wear a hard-hat!).

Maybe this will help:  Knuffi (www.knuffi.com) soft edge bumper guards are a product that is available in both  Photoluminescent  and  Fluorescent.  These foam wedges, angles, and rounds are designed to fit over beam edges and around corners.  They have self-adhesive tape backing so that you can peel-and-stick them to clean surfaces.




You can get these from:

American Permalight (https://americanpermalight.com/safety-bumper-guards/), or

Knuffi. (www.knuffi.com)

These create a personal crumple zone around low-lying beams, shelves, brackets, conduits, air ducts, or other junk stickin'-out around the theatre.  Don't be bonkin' your noggin'!

Be a carpenter with a magnetic personality

Screws, nuts, bolts, nails, tacks, staples, bent nails, and even small tools can be pesky items to keep-up with on stage and around the shop, and if you are up on a ladder (or maybe higher, too) you don't want to drop little items -- it's bad for the people below (yet another reason to ALWAYS wear a hard hat around the shop and stage), you don't want to climb down to get them, and you don't want to find them later by kneeling down on them and imposing significant pain on your kneecaps.
So what's a person to do?  As the 6th century B.C. Chinese military stratigist Sun-tzu wrote in The Art of War:  Keep your friends close, and your enimies closer.  This is pretty easy:  Buy some magnetic wrist bands and tool pouches to keep track of those metal bits that are so easy to drop or mis-place.

MGD Tools (www.MGDTools.com) makes a group of products called Magnogrip.  Made from red and black Cordura with Velcro closures and super stron magnets, they are handy and comfortable to wear.  They offer wist bands, nail pouches, and other handy items.

And for those of you that watch too much late-night TV, the former master of TV huckstersim Billy Mays promoted the Tool Band-it.  Info here: https://www.asseenontv.com/tool-band-it-the-official-site-of-asseenontvcom/detail.php?p=296691&v=daily-deal_20110705

Similar tool bands by Pro-Hold can be found at: www.fastcap.com/estore/pc/ProHold-Magnetic-Wrist-Strap-4p27.htm

Key things to remember:

• Magnetic parts holders are NOT a substitute for lanyards.  DO NOT rely on them at height to protect others below from dropped tools.  Use buckets and pouches that are secure to hold hardware when working at height.  Use buckets with webbing net slings - don't rely on the pail handle to stay secure in a plastic bucket's rim.
• Magnetic wrist bands can really mess-up credit cards and driver's licenses that have the magnetic data stripes on them.  Keep them away from your wallet / purse.  They can also mess with the data on Hard Disk Drives that are in MP3 players, computers and stand-alone data back-up drives.
• Magnetic wrist bands should NOT be worn when working near saw blades or anywhere that moving machinery might draw your hand / arm into the tool.  These magnets can be more powerful than you might think!

Bangin' heads in the workplace

(OzMuseum.com)

At this time of year, football seems to dominate the the national attention as the Superbowl approaches.  Many types of sports present the performers (players) with opportunities for severe head injuries.  It seems like concussions have shown up in every corner of the football world over the past year:  on the field, on locker room posters, in Congressional hearings, in labor negotiations. There's even a blog devoted to them.  Whenever you talk about concussions, you inevitably end up talking about helmets.

Working in theatres is no different. We encounter low-lying beams, pipes, conduit, all-thread, the sharp edges and corners of stage lighting instruments, and the occassional metal flange or rebar sticking out where we least expect it. Of course, we also spend an inordinate amount of time around other people (Remember them? They are the most dangerous thing in the theatre!) that may not be watching where they are going with that oversized chunk of wood, scenery, ladder, or scaffolding.

Wearing a hard hat doesn't make you a geek. Get over the concern about making a fasion statement.  In fact, many theatres REQUIRE that they be worn.

The nature of our work in the theatre causes many of us to spend alot of time bent over working on stuff, so keeping a hard hat on your head can be a bit of a problem.  There is an easy fix for this:  Get a chin strap to keep your hard hat in-place.m  they cost very little and they can keep you from calling HEADS! from the catwalk as your hard hat plumets to the floor below.

One thing to keep in mind when purchasing a chin strap is to look at the clips that attach to the hard hat.  Some products only have a bent metal 'U', while others have a clip type attachment like show here.  These are much easier to keep in place and are highly recommended.

 

ANSI standard OSHA approved hard hats are fairly inexpensive (usually under $10) and the chin straps are even less.  These shoudl be fairly easy to justify for your budget, as a football helmet cost between $50 and $400.

Stagehand Killed By Fall at Rochester Castle Outdoor Concert

July 15, 2010 - Rochester Castle Event Grounds, Medway, Kent, UK.  A man in his 40's fell from the stage and died later at the hospital from the injuries sustained to his head and neck.  The incident occurred about 5:30 PM as the open air concert stage was being prepared.  The Emergency Medical Team received the call at 5:41, and was there within 6 minutes.  They reported that "the patient was bleeding and going into cardiac arrest and was conveyed to the Medway Maritime Hospital."

Police cordoned-off the area around the incident to allow further investigation, and the show featuring Will Young was delayed about 90 minutes.

2002 Pop Idol winner Will Young reportedly said at the end of the show: "Someone's had an accident tonight so let's give him a round of applause and hope he gets better."  He did not know that the man had died and later said he was "shocked and saddened" upon learning of the man's fate.  "I was unaware of the seriousness of the incident until after I left the stage.  My deepest sympathy goes out to the bereaved family."

The cause of the fall and the reason why guard rails did not prevent the injuries are under investigation by the Health and Safety Executive board (HSE) (www.hse.gov.uk).

Wind Gust Uplifts Festival Tent - Six Injured, 1 Broken Leg

What do they tell you?  "Break a leg!"  Not really a good plan for most of us.  The summer music festival season is in full swing and the weather in Tornado Alley can bring-in fairly large storms on short notice.  Tuesday, July 6th had crews setting-up for a Yes and Peter Frampton concert at the Lucky Star Casino in Concho, Oklahoma (about 20 miles west of Oklahoma City) when the skys opened-up and poured down rain with a strong downdraft.

Witnesses say the wind came in under the sides of the tent and pressurized it to lift it up and tear-out the anchor lines.  The wind toppled the sound towers and the overstage truss system as well.

Photo by Nate Billings, The Oklahoman newspaper

Fortunately, the incident occured before there were any audience members present.  The show was cancelled and will be reschedule.

TV Interview with injured crew member:
http://feeds.newsok.tv/services/player/bcpid66319854001?bctid=110205425001

NewsOK web site article: http://www.newsok.com/local-production-crew-talk-about-tent-collapse-at-lucky-star-on-tuesday/article/3474327

Arial footage showing tent site and mangled stage gear:
 http://www.youtube.com/watch?v=p7QMRTpv6V8

A walking tour of the stage and mix tower after the event:
http://www.youtube.com/watch?v=mjRq0jYM6Ok

This video reveals alot about the original set-up.  It shows that the truss bases were not anchored and did not have any ballast weights.  The rig was set-up as if it was an indoor show with no regard to the wind that could blow through and topple the gear if the tent was breached.

Anchor your Rigs!  Watch the weather!  Don't wait for it to hit before you react!

Concert Rigging in Michigan Collapses During Setup - 10 Injured, 2 Hospitalized

During the set-up of a concert stage in the Silverdome stadium in Pontiac, Michigan, 10 workers narrowly escaped death as tons of sound, lighting, drapes, scenery, and trussing collapsed.  Emergency responders from the Pontiac Fire Department were called to the Silverdome around 4:30 p.m. Saturday, June 19th, 2010, before the show started.  The initial call indicated that the domed roof had collapsed, but upon arrival they found that the concert staging framework had caved-in.  Workers recall seeing trusses being hoisted that appeared to be overloaded just be for the mayhem broke loose.  Two workers spent the night on a local hospital for observation.

Some of the most complete coverage if the incident can be found here:
http://www.theoaklandpress.com/articles/2010/06/20/news/local_news/doc4c1d46926f61b990888627.txt
http://www.theoaklandpress.com/articles/2010/06/21/news/local_news/doc4c1fd417969fc357332898.txt

There was no damage to the concert facility as the collapsed rigging was ground supported.  The concert was to be A R Rahman's Jai Ho Concert: The Journey Home World Tour.  Rahamn is best known for his musical score for the movie Slumdog Millionaire.

The concert was cancelled and will be rescheduled.  OSHA was on-site almost immediately to assess the damage and determine the cause of the accident.  With over 150 workers on or near the stage at the time of the collapse, it took some time to determine if anyone was buried under the tangle of wrecked scenery.

The summer tour season is a busy time of year for many stage hands, so for all of you out there bustin' your butt to make a living - keep a close watch on your co-workers and guests.  Don't hesitate to recognize potential hazards and notify the proper authorities if you see unsafe conditions.  Your life depends on it!

Procedural items to remember:

• Preplan your show - Know your rig - and all the weight that is attached to it.
• Verify your show - Use load cells to measure truss hoist loads.
• Have spotters on radios monitoring (this means listening, too) all viewpoints during lifts.
• Always clear the stage and call for quiet during lifts.
• Have a gathering point (muster point) pre-arranged just in case there is an emmergency like this.  Don't have people wondering around afterward until you have a clear head count.
• Where bright clothes during set-up and strike (it makes it easier to find the body) - save your blacks for the show.
• Wear your PPE:  Boots, Hard Hat, Safety Glasses, Gloves, at a minimum, knee pads, and fall protection harness as required.
• Don't work when you are worn-out or heat exhausted.  This seriously impairs your judgement.  Stay hydrated.

Rung for your life!

Ever have to make one of those reeeally long ladder climbs?  Didja wonder if you were ever going to get to the top (or the bottom, for that matter)?  Your hands can get sweaty and your boots might have a bit 'o crud on them . . . you get a bit tired . . . next thing you know:  you lose your grip, or your foot misses the mark.  This may be an annoyance, or it could be a lot worse.

Fall protection systems for ladders are only required for ladders more than 15 feet tall (you can see the harness attachment rail at the center line of this one).  This may keep you from falling to the ground, but you may still bust your face on the ladder before you regain you composure (yet another good reason to have a chin strap on your hard-hat!).

Many of the ladders you may encounter are right at or just short of the 15 foot limit, so all you have to protect you is your good grip on the ladder.  You can install fall arrest devices on ladders less than 15', too, and it is a really good practice.

Safeguard Technologies has a solution:  Formed fiberglass overlays that are fabricated to fit a variety of ladder rung diameters from 3/4" to 2" diameter.  The covers have hi-traction grit embedded in the material to provide a slip-resistant texture to the surface.  These can be applied to scaffold climbing rails, too, which are notoriously slippery - why do the scaffolding manufacturers coat these with glossy powder-coat paint?!

A ladder rung cover being installed with adhesive.

Ladders rungs nicely visible and with very high traction.

Now for the cool part:  Since these are made-to-order to fit the rung width and rung diameter of your facility's ladders, they can fabricate the rung covers with photoluminescent pigment in the fiberglass binder.  This can help you find your way down from the catwalk or gridiron in the dark should the power go out.

Resource:  Safeguard Technology (http://www.safeguard-technology.com/)

You can Huff and Puff, but you won't blow down this Brickhouse

Say what you will about counterweight rigging being medieval, it still goes into a lot of stages and is used every day by many people.  So, if you're going to do it, you might as well make it safer.  At USITT 2010 in Kanasas City, Thern Stage Equipment Company introduced the "Brickhouse Front-Loading Counterweight Arbor System".  This takes a whole new approach at how you handle the counterwights as they are loaded and unloaded, and also takes a new look at securing them in the arbor carraige.

The first thing one notices it that the Brickhouse has side walls and three compartments for counterweights.  This allows you to load weights into the most convenient compartment to access, rather than reaching high or low and possibly overextending oneself.

The next convenience is that as you place weights in the Brickhouse, you don't need two hands to do it.  No awkward twisting, tilting, or finagling of the weights to get them in-between the arbor rods.  Why?  Well, there is no back rod, and the front rod conveniently swings out of the way so you can just slide the weight 'bricks' into the compartment, which is sloped a bit to help with the process.

The weights have a handle built right into them, too.  What a concept:  A counterweight that you can grab onto with one hand and hold it securely without fear of dropping it.  This leaves your other hand free to hang-on for dear life (you are wearing a fall prevention / arrest system as you load weights, right?)

Once the weights are nestled into their compartments (and you can fill the compartments all the way to the top, too), you just swing the front arbor rod back into place and let 'er fly.

Drop testing shows that a stage heavy line set will crash throught the lower arbor stop just like a regular arbor (no surprise there), however, the side walls are built to take a lickin'-and-keep-on-tickin', so you shouldn't have a mess of bricks jumping out of the Brickhouse.  No word yet on the potential for bricks jumping out of the Brickhouse in the event of a stage-heavy run-away, but given the design of the compartments, it looks like the weight-lock free design still keeps them under control and not raining-down a hail storm of steel plates on the fly crew should a line set get away from you.  That said, I'm still wearing my hard hat PPE when I'm onstage or in the fly galleries - there are still a lot of other hazards out there to ping your skull.

More info can be had at: http://www.thernstage.com/products/rigging-systems/counterweight-systems.html

Glow-in-the-dark Brain Buckets

As I have mentioned before, Hard-hats are a really good idea in the theatre. There are lots of sharp corners, low-lying steel beams, and stage lighting instruments that can leave a real bonk on yur noggin.  3M has combined the photoluminescent pigment technology with a standard hard-hat to create a nifty lil' skull protector.

3M™ Glo-Mega™ Omega II GLO Photoluminescent Hardhat.

Of course, we theatre folks tend to spend alot of time leaning-over with our heads pointed down.  So,if you buy a hard hat, spend the extra buck-n-a-half for a chin strap so you won't be hollerin' "HEADS!" as you watch your PPE fall to the floor below . . . those built-in head-bands don't work so well when you are inverted.

OSHA Head Protection Regulations 1910.135 and 1926.100

Breaking strength of copper wire vs. steel cable - Gee, which one would you choose?

This scenery flat was found attached to a utility batten with a loop of 12 gauge stranded copper electrical wire. Copper is a soft metal that has little strength when loaded structurally. The director usually doesn't want the performers to wear hardhats during the performance, so eliminating the possibility of scenery falling on them really can work-out well for the wardrobe department.

The use of proper scenery attachment clamps, and securing flats at the bottom as well as the top can improve the safety. By attaching suspension cables both places, the flat framing is loaded in compression, rather than in tension, greatly reducing the likelihood that the flat could be pulled apart at the seams / joints should it snag on something when it is going up (flown-out).

Thread the suspension cable through this at the top of the flat.
Terminate the suspension cable at the bottom with a bracket like this.

Components shown found on Doughty Engineering web site (www.doughty-engineering.co.uk)

Could you sharpen that stick a little bit more - I'm not sure it will fully pentrate my skull!

All-thread rod that protrudes below the air duct mounting bracket - cut an an angle to ensure damage to anyone that dares to come near . . . yet another reason to wear a hard-hat!