CPAC Safety Manual
II. Counterweight Fly System
The counterweight fly system is a dangerous piece of equipment that has proven to be lethal in many reported cases. Injuries involve people falling and things falling on people. Only those trained in its proper use may use the system.
Before unlocking a line set, operators must first check that the set is in balance
by feeling the tension in the front and back ropes. If a line set is out of balance
the operator will need to make choices about how to safely move it.
Wearing well fitted gloves will help protect the operator's hands while using the
system.
Before moving a line set, the operator communicates with everyone on deck, on the
loading rail and on the grid alerting them to the fact that a line is moving.
“Heads on Stage Line Set 11 coming in” or “Line Set 11 going out”
Before moving the line set the operator waits for acknowledgment from the loader
and someone on stage representing the working crew. When the loading rail and grid
is clear the Loader will give the clear command.
“Clear” or “Loading Rail Clear”
If there is a crew onstage someone representing the crew will check that no one is
in danger of injury and indicate to the operator that the deck is clear.
“Clear for 11” or “Deck Clear for 11”
The crew leader on deck is responsible for all members at the stage level including
the ones that enter after the process has begun.
Setting up the fly system will involve many people, the minimum being three, two people
on the loading rail, and one operator at the fly rail.
The operator or a stage carpenter will communicate the line set to be loaded/ unloaded
and the amount of weight to be changed.
“Load 100 lbs on line set 15” or “Unload 50 lbs from line set 15”
Before changing weight the Loader repeats the instructions and then commands that
the rail be cleared.
“Adding 100 lbs to line set 15, CLEAR THE RAIL”
After moving away from the operating rail and making sure everyone else is clear
the operator or lead stage carpenter communicates with the loaders that the rail is
clear and that it is okay to load. The operator/ lead carpenter alerts anyone who
happens upon the scene that loading is taking place and clears them from the fly area.
“Rail clear, OK to change weight”
When the weight change is completed and the loader is clear of the system, the loader
communicates that they are finished.
“Loading complete”
The Operator then acknowledges the Loader.
“Thank you.” or “Checking balance on line set 12 etc.”
If the load is not balanced more weight must be added or removed. We say the line
set is either arbor heavy or batten heavy and thus begin the process again from step
one.
The loaders are responsible for the safe handling of weight. Stage weights can weigh anywhere from 26 to 52 pounds apiece. A weight falling 50’ can be lethal and can severely damage equipment. NEVER stack stage weights above the height of the toe rail on the loading gallery.
The operator is responsible for securing the lineset prior to weight change. The locking rail is not designed to hold severely out of weight line sets, but to keep them from drifting when they are mostly balanced. Do not count on the rope lock when changing a lot of weight. When changing more than 50 lbs it will be necessary to use an alternate locking technique (i.e. using a prussic knot, a snub line, or an Uncle Buddy®).
The Stage Carpenter is responsible for managing weight changing activities and keeping the deck safe from all hazards associated with the fly system.
Only hardware that is rated for flying will be used to fly equipment and scenery. Most of what you can purchase through big box DIY centers are not properly rated and will not be allowed. Cables and wire rope must be free of kinks or frays, hardware must be free of defects; they cannot have been previously overstressed.
It is possible to lose control of a severely out of balanced line set. If this occurs, do not try to grab onto the rope! Yell “RUNAWAY” very loudly and clear yourself and others away from the loading area and the area onstage under the batten.
