I think I'll go strapless on the catwalk today

Your nemesis - Expanded Metal Grating.

And his side-kick - Bar Grate.

Wurk Pads from the front.

 Working on the Gridiron Deck, Loading Gallery, or Beam Catwalk is not usually all that glamorous, but you can make a fashion statement that is functional and comfortable.  Who knows, maybe you will turn a few heads while wearing these Wurk Pads?  For some unknown reason, masochists must design these work surfaces, as someone that works upon them would never let this happen.  Theatre crews spend way too much time on their knees, and anything you can do to relieve some of that suffering is a good thing.

Wurk Pads - the secret revealed.

The key design element is that they use heavy duty clips that grab your pant legs and won't let go (well, unless you tell them to).  So, wa-la!  Nothing sneaking around behind the crook of your knees to bind-up and get all sweaty.  Sweet!  No sweat.

This can come in handy if you have big feet, too, as some over-the shoe knee pads just won't open-up far enough to slip over your work boots.  I suppose that if you had to work for a stretch on your hiney, you could clip one to each cheek and give them some relief, too.

Knee pads aren't just for crawling around on the steel, either:  the stage and shop floor can harbor small screws, nails, tacks, and other pebble-sized objects that can render your brain useless should you set your full weight down on them via your knee-cap, so put these in your PPE kit - and don't kowtow to anyone without them.

More info at:  http://simplifiedsafety.com/store/wurk-pad-clip-on-strapless-knee-pads.html

Grip Like a Gorilla

The ergonomics of loading counterweights place your hands at risk of being crushed and  banged about pretty badly.  You need to both protect your hands from outside abuse and to keep a good grip on those steel bricks lest you let one slip away and kill someone below.

Showa-Best Glove Company has a good solution to that problem.  Their S-Tex 300 and S-Tex 350 work gloves have rubber or nitrile palms for good grip, and they come in a safety neon yellow your buddy on the Loading Gallery doesn't forget where your hands are and plop a 20 pound brick down on one or both of them.

Showa-Best Glove S-Tex 300

Besides being bright and grippy, these gloves have a very high puncture resistance rating, tear resistance rating, and blade cut rating, so they can be very handy (forgive the pun) around the shop when handling glass, sheet metal, and replacing saw blades (NOTE:  never wear gloves when actually using a power saw or power drill - one snag and it'll pull your hand right into the blade or bit).  The open mesh back keeps your hands cool, too.

More info at:http://www.showabestglove.com/site/products/detail.aspx?style=S-TEX300 and http://www.showabestglove.com/site/products/detail.aspx?style=S-TEX350

Get a Grip

206 Reasons for Fall Protection

This, of course, doesn't include the medical or funeral expenses,

loss of work or life, and the time spent cleaning-up the mess.

Resources:

Capital Safety - en.capitalsafety.us

DBI-SALA Safety - http://www.dbi-sala-safety.com/

FallTech - http://www.falltech.com/

Guardian Fall Protection - http://www.guardianfall.com/

Miller Fall Protection - http://www.millerfallprotection.com/

MSA Fall Protection - http://www.msanorthamerica.com/

RTC Fall Protection - http://www.fallprotection.com/

OSHA - http://www.osha.gov/

Chutes and Ladders

Ladder wells can be dangerous places, as they are a transition point from a stable work space and a location where you are on uneven footing and must use your hands as well as your feet. In the picture below you can see a ladder-to-catwalk transition that does not meet the ANSI standard / OSHA required railing arrangement. You have to climb between the railing and the toe board (kick-plate) to make the transition. It is really quite awkward, and therefore, dangerous.

Here is a ladder transfer platform that is clearly marked and has a spring-hinged safety gate.

PS Doors Safety Gate

This is a gravity-hinged safety gate.

Intrepid Industries DG series Safety Gate

As mentioned in other posts, it always a good idea to have both emergency lighting (i.e. 'frog-eye' battery-powered light packs) and photoluminescent marking stripes along your catwalks and ladders so when the lights go out and your battery-pack fails, you still can find your way to the ladder - and down it.

Resources:

Intrepid Industries (www.intrepidindustries.com/Index_Gates.htm)

PS Doors (http://psdoors.com/safetyProduct.php?item=LadderSafetyGate)

ANSI A14.3 - "American National Standard for Ladders−Fixed−Safety Requirements"

OSHA - U.S. Occupational Safety and Health Administration – "Regulations 29 CFR 1910 Subpart D (Walking-Working Surfaces)"

PIP - Process Industry Practices document "STF05501 - Fixed Ladders and Cages"

Ladder, ladder, on the wall . . . how many ways can you make me fall?

This ladder may have been 'legal' when it was installed (probably circa 1951), but it doesn't meet today's ANSI / OSHA standards.

For starters, access is on a platform that is about 8 feet above the stage (not visible, but off to the left of the ladder). There is no railing along the edge of this platform. To correct this situation (other obstacles to come, stay with me), a safety railing would have to be installed to protect the worker on the platform, then a cage would have to be installed to enclose the ladder. Since the ladder is almost adjacent to the railing, additional guards would have to be installed between the top of the railing and the bottom of the ladder cage so that the worker could not fall over the railing as they climb the ladder.

Note that there is also a wire-guided line set intruding into the climbing space of the ladder.

The next thing that is encountered is the opening through the proscenium wall. A platform is required here so that the worker can enter the door without hanging off of the ladder.

• Side note: The door was found open, thus violating the fire wall integrity. This door is a 'shorty' - its only about 48-50" tall. They built them that way to meet the square footage requirement for penetrations through the fire wall. Curious, as there never was a fire curtain installed to separate the stage and house - why would they worry about the size of the fire door?
• Second side note: On the other side of the fire door there was a light switch to illuminate the attic catwalk, but if you didn't know this, you would enter in the dark to find a 2 foot wide catwalk that turns immediately left. This catwalk has no guard rail or toe boards, beyond which was about a 20-25' drop down into an interior wall void that goes all the way down to the auditorium floor level. If you fell down in there they wouldn't find you until your body started to stink-up the place. Don't fall in on the last day of school - you'll be there all summer! Did I mention that all of this was fully accessible to the students?
• Third side note: There was no grab-rail or anything to get a hold upon as you climb off the ladder into this 'shorty' door way - you have to reach in blindly and get a grip on anything that you can feel for - that was scary. Climbing back out of the door to get on the ladder was 'fun', too!

So, assuming you have added the requisite landing at the attic access door level, you now have to get up to the gridiron level. The existing ladder over-hangs the access door opening on the right, and runs into the headblock beam on the left. Time to re-group and think this over.

Plan B: Lets put the ladder to the right of the door, far enough off-stage that you can go past the electrical conduits with the proper clearance. This way we don't need the railing-to-ladder-cage filler panels, and we get out of the way of the wire-guided line set. We would have two platforms: One at the access door level, and one at the gridiron level. Of course, both platforms will require proper railings.

When you connect the platform to the gridiron you find that there is no railing along the headblock beams. (Imagine climbing the existing ladder, working your way around the off-stage headblock beam, over the loft well between the headblock beams, only to find that the gridiron was built with 2x6's set on-end with about 6" gaps between them. So much for having a good footing and a 'non-combustable' structure . . .)

Oh yeah, did you notice that there was NO loading gallery? Need to add one of those, too. Looking at the picture you can see that a loading gallery floor would likely encroach into the platfrom area for the attic access door. Dang! Wuddle we do?

We could use all motorized line-shaft rigging, but that is a fairly expensive solution. The saving grace is that the facility is now a 6th-grade only school that does not have a theatre arts program. The wire-guided rigging system was pretty well shot, and all the drapes need replaced, so the movable rigging will probably all go away and the battens will be dead-hung. The facility still needs a proper ladder access to the attic and gridiron, but at least it won't need a loading gallery, too.

One last note: Did you see that 2x4 fluorescent light fixture bolted to the bottom of the wood 'gridiron' joists? There were about a dozen of those that need to be serviced . . .

A Long Way To Fall - Ladders Without Cages

This is a legacy ladder which was installed before OSHA even existed. However, that does not exempt the owner from correcting the situation. Ladders of this height must have an ANSI standard cage around them and a fall protection device installed.

Fall protection can be provide in two ways:

a.) There can be a continuous cable or track that runs the length of the ladder (usually up the centerline) with a special trolly attachment that ties to the front of the worker's fall protection harness.

b.) There can be a retractable fall arrest lanyard secured above the top of the ladder way that attaches to the back of the worker's fall protection harness.

Since the worker has to transfer backwards from the ladder onto the catwalk near the top, the retractable fall restraint would probably be the safer solution. Otherwise, the worker would be required to attach a secondary lanyard to the catwalk fall protection anchorage point before he could disconnect the front trolley and he would have to do that while standing on the ladder.


At the top of the ladder you can see that there is a fire sprinkler pipe crossing the travel path of the worker. This would have to be repositioned to provide proper clearance for the ladder cage. Right above the sprinkler pipe is the end of the Loading Gallery catwalk, which would also have to be moved back to allow a clear passageway. Fortunately, I had on my hard-hat when I climbed this ladder -- when I reached the sprinkler pipe I hit my head hard enough to dislodge the inner suspension. Had I not been wearing the hard-hat it could have knocked me out or made me lose my grip on the ladder.

A secondary problem with this stage design is that a full fly house really should have a Lower Loading Gallery in addition to the Upper Loading Gallery. The Lower Loading Gallery is typically situated about 10-12 feet (~4m) below the Upper Loading Gallery so that weights can be added / removed from the counterweight carriage (arbor) when the batten is about the height of a backdrop and/or scenery flat.

Of course, once the ladder has a cage around it and the end of the catwalk is repositioned, it will need a safety gate at the catwalk to keep someone from inadvertently stepping-off into the open hole. Something like this (from a different facility):

If you look closely you will see several interesting items in this picture:

• On the left side (on stage), there is a railing that meets the 4" sphere rule (as if there was going to be a baby crawling around up there !? I guess they figured it was OK if the baby crawled under the safety gate . . .). There should be a steel plate or mesh that extends up about the 18-24" level to prevent the unused ( stored) counterweights from spilling over onto the stage floor below. Also note the 'stored' counterweight left along the off-stage side of the catwalk as a trip-hazard.
• The on-stage side railing is also about 40" tall, enough to keep you from falling over it. A 42-48" railing would be more appropriate here.
• On the right side (off stage, toward the counterweight arbors) there are railings at 8", 24", and 40". Just enough of them to keep you bonking your head as you try to man-handle the counterweights. There is not any OSHA required fall protection anchorage to allow the worker to wear a fall protection harness and safely lean-over the railing and do their work.
• The floor of the Loading Gallery is fabricated from open pattern bar grate, which acts like a cheese grater on your knees when you kneel down on it. It is also open weave, so any grit on your shoes gets scrubbed-off and drops onto the crew working below you. A better solution is to have a closed floor decking (sheet metal) that has a dense rubber mat on it. This provides a non-slip surface, is quieter when setting-down counterweights, and keeps the grit from raining down on those below.
• And the coup de grâce is that there is not an Index Strip Light at this level, so you are working in the dark (all that light you see is from the camera flash). There wasn't any emergency lighting packs either, so if you get caught up there in the dark, good luck getting down!

As a side note, it is always good to paint the working surfaces facing the catwalks a light color like white. This is good for floors, railings, uprights -- everything. If the masking drapes are all properly positioned, no one will see the catwalk from the audience seating area. Place glow-in-the-dark marker tape along all gate and floor openings so you can find your way out in the event of a total power failure.