Counter-weight Fly System Inspection Checklist

Notes from a seminar by Jay Glerum (Author of "The Stage Rigging Handbook") on 3/24/2000

Safety inspection checklist

1. Hand lines - inspect for
abrasion, moisture and inspect knots.

2. Arbor

Top & Bottom
Rods & rod nuts
Spreader bars & lock plates
Hand line knots
back plate
guide plate
D.P. top and bottom blocks

3. Head & Loft blocks

Mounting clamps
Support steel
Bearings (listen)
Side plates & retainers
Fleet angle

4. Tension Pulley

Travel and guides
Bearings & shaft
Side plates & castng

5. Lock Rail (give it a good kick
to make sureit's anchored securely)

Mounting bolts that hold the rail
Rope lock mounting bolts
Lock rings

6. Rope Locks

Tension adjustment
Handle
Jaws
Casting

7. Wire Rope

Abrasion (sag bars & idler pulleys)
Broken wires
Termination at both ends
(knots, Crosby's, nico-sleeves.
Check each type for proper connections.)
corrosion

8. Battens

Splices
Level
Straight

9. Winches

Gear box
Drum
Limit switches
E-stop

Make a checklist for inspections. Conduct your inspection when the space is quiet. Run each line set to listen as well as visually inspecting the following:

Battens: terminations, splices, and ropes.
Rail: locks, lines, t-rails, stops, arbor bottoms, arbors, arbor tops, pulleys.
Head Blocks: t-rails, stops, terminations.
Make a Repair List to check off.
Make repairs.
Enter information into Rigging Log

     California and 11 other states require Maintanence & Repair Logs. If an OSHA inspector comes in (either before or after an accident) and none is present, the responsible party won't be cited, they will be arrested.
     A rigging inspection should provide a "resonable expectation of safety". It should be done by a "competant" person (one who knows the current and predictable hazards and has the authority to make corrective change). The general rule of thumb should be,"if it looks bad, or sounds bad, it is bad. If an inspector discovers a fault and authority above demands continued use of that element of the system, it is advisable to have that authority sign a "Memo to Hold Harmless" accepting the liability (and absolving the inspector).
     It is further advisable to have a written policy on inspection and maintanence for a venue. Minimal inspection interval should be one year. Policy should include using name-brand, rated hardware (to put the liability of hardware failure onto the manufacturer). The load-limit of each piece of hardware should be available to users. Users should be encouraged to defer to competant riggers in cases of questionable competancy within their own group.

This is by no means an exhaustive list, but rather, a foundation to build upon as required.

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