HomeMy WebLinkAbout2004-04-05-tcc-theater-equipmentTheatrical Lighting and Rigging Systems Supplement
The following descriptions apply to the integration of specialty performance lighting and rigging equipment for
Theatrical and Performance spaces. Any specific equipment noted shall be considered basis-of-design and
shall be used as a guideline in the design process for quality, function, and performance regardless of
availability at the time of procurement. Equipment that has been discontinued shall be substituted for the
current equivalent version to be approved by TCCD. The project specific Contract Documents shall be
developed on a case-by-case basis to consider current equipment availability and specific campus needs, at
the direction of TCCD.
The following descriptions are to be used as a guide for campus specific design.
11 61 33 – Theatrical Rigging Systems and Stage Draperies
A. Qualifications
1. Where Specialty Theatrical design scope is identified, The A/E design team shall include an
American Society of Theatre Consultants (ASTC) Theatre Consultant with extensive previous
experience in university/college building design environment. Additionally, rigging system design
and assessment work shall be conducted under the supervision of an Entertainment Technology
Certification Program (ETCP) Certified Theatrical Rigger.
2. The contractor shall place and maintain on the project a sufficient number of skilled installers
who are thoroughly educated and experienced on the necessary crafts and completely familiar
with the specified requirements and methods needed for the proper performance and completion
or the work.
B. General
1. All theatrical rigging equipment shall be of a high-quality manufacture and rated for the intended
use by the manufacturer.
2. Products shall be new, free from defects and listed by an NRTL when an applicable NRTL
Standard exists. Provide product of a given type from one manufacturer.
3. Model numbers and manufacturers included in this guideline are listed to establish a standard of
function, performance, and quality.
4. All equipment, installations, and functional elements shall at a minimum meet all applicable ANSI
standards, codes, and requirements for safe and proper application.
C. Form-Factor Basis-of-Design
1. Performance Auditoriums shall at a minimum meet the following design form factors:
a. Over stage rigging shall consist of hybrid system of single-purchase counterweight linesets with
motorized hoisted stage electrics
(a) Number of linesets and capacities shall be determined by system design in a specific space with
specific architecture.
(b) Additional loose or auxiliary equipment shall be provided, as needed, through the design
process. This equipment shall not be considered as part of a standard installation package.
b. Any necessary front-of-house (FOH) lighting support systems shall use a motorized-hoisted form
factor
2. Black Box, White Box, or Studio Theatres
a. The entirety of the room shall be covered with a pipe grid for support of temporary lighting, scenic,
or drapery loads
(a) Pipe Grid shall be assembled with 1-1/2” Sch40 plain end steel pipe
(b) Pipes shall be in a nominal 4’x4’ grid with hangers to structure every 6’-0”
(c) Pipe grid shall be mounted at a nominal 16’-0” Above Finished Floor (AFF)
(d) Pipes shall be rated for 25lb/lf of user applied load
b. A set of black velour masking panels shall be arrayed around the room. These shall be divided up
into sections not-to-exceed 10’-0” in length.
(a) Drapes shall mount to straight walk-along curtain tracks
(b) Drapes shall be mounted a nominal 3’-0” away from a wall, but this is dependent on specific site
conditions.
D. Rigging Equipment Requirements
1. Counterweight
a. Head Blocks:
(a) Number of lift lines required by the design
(b) 12-inch diameter cast-iron sheaves shall be fitted with 1” tapered roller bearings,
properly sized for the required load and speed. Grooves shall be sized as required for
operating components.
(c) Side plates shall be 10 gauge steel plates welded and bolted to base with hardware to
prevent lines from leaving their grooves.
(d) Steel base angles and clamping hardware shall be designed to accommodate the
loads imposed by the rigging system and be designed to mount on the structure
provided.
b. Loft Blocks:
(a) Size: 8” diameter Nylatron sheave shall be fitted with 5/8” ball bearings, properly sized
for the required load and speed. Grooved for wire rope required for designed loads.
(b) Provide quantity as required.
(c) Provide integrated idler pulleys as required.
c. Tension Blocks
(a) The cast iron sheave shall have a 10” outside diameter with a machined groove for a
¾” rope.
(b) Blocks shall have a minimum weight of 40 lbs. to properly tension the hand line.
(c) A kick tab shall be provided to permit adjustment of the rope tension.
(d) Blocks shall mount to the guide track by two matching guide shoe assemblies.
d. Counterweight Arbors
(a) Provide a steel assembly designed to carry counterweight and to terminate wire-rope
lift lines and operating lines on a matching guide track.
Theatrical Lighting and Rigging Systems Supplement
(b) Arbor lengths shall be adequate to accommodate the counterweight stack necessary to
balance to balance the lineset’s specified load capacity.
(c) Arbor tops shall be a 1/4" steel plate formed into a channel with 3" sides. Channel shall
be punched to terminate lift lines and to accommodate a bolt and spacer providing a tie
off point for the hand line.
(d) Arbor bottoms shall be of similar construction, with counterweight rests to keep the
weights from resting on the inner arbor rod nuts.
(e) Two 3/4" diameter steel arbor rods and a 3/8" x 3" steel back plate shall fasten between
the channels. The arbor rods shall have three nuts at each end, the outermost being a
lock nut.
(f) Provide two guide assemblies secured to each arbor. Guides shall be UHMW-PE
between steel backing plates.
(g) Provide a minimum of two spreader plates adequate to stack between counterweights
on 2-foot centers. Provide a retaining collar with ¼” set screw on each rod. Label the
arbor to indicate the proper locations for the spreader plates.
e. Arbor Guide Tracks
(a) Provide a system of extruded aluminum J-shaped guide tracks mounted to the wall of
the stage to accommodate the travel of the counterweight arbors as described on the
drawings.
(b) Guide tracks shall be fastened to horizontal wall battens having a maximum center
spacing of 5’-0”.
(c) Wall battens shall be attached by adjustable knee brace assemblies designed to
accommodate irregularities along the mounting wall.
(d) Install arbor stops across the guides at the top and bottom limits of travel. Stops shall
be minimum 1 3/4" x 1 3/4" x 3/16" steel angle. A nominal 2" x 2" hardwood bumper
capped with a ½” thick rubber strip shall bolt to the arbor stops.
f. Counterweights
(a) Fabricate counterweights from flame or laser cut steel plate as described on the
drawings. Finish free from slag and sharp edges.
(b) Size: nominal 6” wide X 14” long and slotted to accommodate the specified arbor rods.
The thickness of counterweights shall not vary more than 3/16" from nominal dimension
(c) Finish: weights used to balance the empty pipe batten shall be painted red. All
remaining weights (those used to balance live loads) shall be painted black.
(d) Counterweight shall be stored on the elevated loading platform.
g. Locking Rail
(a) Provide an elevated locking rail punched to receive rope locks desired center
dimensions
(b) Rope locks and index cards shall be mounted on a formed steel angle no smaller than
3-1/2" x 5" x 1/4".
(c) The onstage edge of the rail shall be sloped and punched to receive formed clips which
hold index cards centered on the installed sets. Provide one numbered plastic write-on
card for each installed set.
(d) The entire locking rail shall be designed and installed to withstand a minimum up-load
of 500 pounds per foot.
h. Rope Locks
(a) Provide rope locks fabricated from ASTM A536 ductile iron including housing, cams
and handle. The housing shall allow the use of a standard padlock to hold the handle in
its closed position.
(b) In order to reduce noise during operation, there shall be a rubber bumper in the
housing to silence the handle when it is opened. The dogs that grip the rope shall be
machined to fit closely to reduce noise, and shall not require the use of washers.
(c) Adjustment for rope shall be from 5/8" to 1" by means of a ½" nylon tipped, socket head
adjustment screw with lock nut at the rear of the housing.
(d) The handle shall be 9" long with a nylon powder or vinyl dip coating. The handle shall
be installed so that it passes two degrees past vertical to lock the hand line.
(e) A coated, oval, welded steel ring shall be provided as a safety lock.
(f) The rope lock shall mount to the locking rail with four 3/8" hex bolts and lock nuts.
i. Operating Line
(a) Provide a three-strand twisted rope constructed of filament and staple/spun polyester
wrapped around a polyolefin core.
(b) Minimum tensile strength: 10,500 lbs
(c) Color: white
(d) Size: ¾ inch diameter
j. Index Strip
(a) Provide an integrated LED index lighting strip fixture suspended above the locking rail.
(b) The lighting strip case exterior shall be finished flat black.
(c) The fixture shall support two-circuit operation (both white and blue). Integrate the fixture
with the stage lighting system.
2. Fixed Speed Hoisted Battens
a. The hoist shall lift the batten at a fixed nominal rate of 20 ft/min.
b. The drive motor shall be flange-mounted (NEMA C-face) to a speed reducing gearbox
sized to drive the specified load. The use of chain sprockets, timing belts, or similar non-
integral connections in the power train is not permitted.
(a) Gearbox assemblies must have double shaft seals or be provided with drip pans.
(b) The gearbox shall have a minimum service factor of 1.25.
(c) The motor shall be equipped with an integral spring-set, electrically released brake
capable of providing a retarding torque of at least 200% of the rated full load motor
torque. The brake must provide fail-safe operation in holding the load while the motor
coils are de-energized. The motor control scheme must ensure that the brake not
release unless the motor has developed adequate holding or lifting torque upon
energization. The brake shall have a provision for manual release for use in
commissioning and maintenance.
c. Each lift line attached to a batten will spool onto an individual steel drum driven by a
common shaft.
Theatrical Lighting and Rigging Systems Supplement
(a) Drums shall be fabricated from steel pipe or tubing sized of a thickness suitable to the
load, and long enough to store wire rope sufficient to allow the specified load travel
plus three additional wraps in a single layer.
(b) The drum shall have a helical groove sized properly for the specified wire rope and with
a minimum pitch diameter of 30 times the rope diameter.
(c) The drum will couple to the driving shaft using a welded flange and appropriately sized
key and keyway.
d. The drive shaft must couple directly to the output stage of the gearbox. Shafts shall be
supported along its length with self-aligning bearings as necessary.
e. The hoist must have a redundant braking system. This may be implemented as a
mechanical over-speed brake attached directly to the drive shaft. The over-speed brake
shall be sized and adjusted to lock rotation of the hoist shaft should it rotate faster than
the nominal design speed of the hoist. This brake shall engage in the event that the
motor-end brake, gearbox, other rotating or electronic components fail and cause the
hoist shaft to rotate freely and in an uncontrolled manner under load..
f. Each hoist shall be equipped with an industrial rotary cam limit switch assembly which
will provide normal end-of-travel and emergency over-travel signaling to the Control
System. Traveling-nut type switch assemblies are not acceptable for use.
(a) The limit assembly shall provide four (4) normally closed (N.C.) contacts, two for each
direction of travel as noted above. The position of each contact opening along the
distance of travel must be individually adjustable in the field.
(b) Selection and gearing of the limit assembly must allow the driven load to stop at a
repeatable position with ¼ inch of accuracy.
(c) Limit assemblies may be directly coupled to the drive train, or may be driven using
roller chain or toothed (timing) belts with the provision that these latter are fully
guarded.
g. Each hoist must have a local means to disconnect its motor from the power supply
h. Provide wireway, cabling, and connectors for separate low-voltage control circuits and
power to each hoist. Cabling shall conform to the hoist manufacturer’s specifications.
i. Lighting Equipment Integration
(a) Cable Management
(i) A means to provide a permanent electrical connection for the lighting system
circuits on the over stage lighting battens shall be provided
(ii) The suspension system shall raise and lower the electrical cable as it travels with
the batten.
(iii) The system shall allow the batten to move without disconnecting electrical cables,
and without fouling any component of the hoisting mechanism.
3. Fixed Lighting Pipes and Pipe Grids
a. Pipe assemblies shall be constructed of new ASTM A53/A 1-½" nominal schedule 40
plain end steel pipe.
b. Pipe Grid Configuration:
(a) Cross-over Clamps - Intersecting pipes shall be joined with specialty hardware to
clamp, join, and support pipe-grid segments. Clamps shall have a recommended
working load of at least 1,500 lbs. U-bolts are not acceptable.
c. Each pipe shall terminate just off the wall. Internally sleeved wall plates shall securely
brace the grid against the wall once it is in place. Supply sufficient braces to prevent
lateral movement of the pipe grid.
d. Suspension - The grid shall be rigidly hung from the overhead steel structures on centers
at nominal 6 ft. x 6 ft. intervals, and not exceeding 8 feet in either direction.
4. Rigging Hardware and Accessories
a. Pipe Batten Assembly
(a) Pipe battens shall be constructed of new ASTM A53/A 1-1/2" nominal schedule 40 plain
end steel pipe.
(b) Battens exceeding one standard pipe length will be joined using an internal splicing
sleeve. Splices must provide the same overall capacity, deflection, and strength to the
pipe battens as an un-spliced span. Threaded couplers are not permitted.
(c) Splice sleeves shall be a minimum of 24" in length with a minimum of 12" extending into
each pipe batten.
(d) Sleeves will be machined to a diameter that will create a snug fit within the pipe battens.
(e) Splicing sleeves will be fastened to the pipe batten with pins or 3/8” diameter bolts.
Locate at least two fasteners on each side of splice joint; alternate direction of fasteners
at right angles to one another across the diameter of the pipe.
(f) Any fasteners used on pipe battens must meet SAE grade 5, and be equipped with self-
locking nuts.
(g) Cover the end of each batten with a yellow or white closed end, soft vinyl safety cap at
least 4 inches in length. Cap shall display linesets maximum capacity, and lineset
number.
b. Batten Connections
(a) Wire rope lift lines shall terminate directly to trim chains constructed of NACM chain
certified by their manufacturer as suitable for the intended purpose.
(b) Chain shall be ¼" diameter or larger, and of sufficient length to wrap one and one-half
times around the pipe batten and return to the eye of the wire rope lift line.
(c) One chain end shall be terminated directly to the wire-rope eye, the other end secured
with a forged screw pin anchor shackle rated for the intended purpose. The screw pin
shall be moused or seized to ensure the pin will not release.
(d) Where a pipe clamp may be required on a batten, a wrap-around type clamp shall be
provided. This clamp shall be secured to the pipe using SAE 5 grade bolts, washers,
and self-locking nuts.
c. Wire Rope Lift Lines
(a) Provide lift lines and fittings appropriate for supporting the load requirements.
(b) Lift lines shall be a minimum of 1/4” diameter 7 X 19 construction, galvanized aircraft
cable with a breaking strength of 7000 lbs.
(c) All wire rope must be new; damaged or deformed cable may not be used.
(d) Exposed ends of wire rope shall be cut cleanly, then seized.
(e) Wire Rope Termination
Theatrical Lighting and Rigging Systems Supplement
(i) To connecting hardware, form eyes around an appropriately sized thimble using
copper Nicopress® compression sleeves.
(ii) To cable drums: terminate the wire rope on the inside of the lifting drum using a
Nicopress® compression stop sleeve.
(iii) Supply and install compression sleeves or clips in size and quantity per guidelines
set forth in the Wire Rope User’s Manual, by its manufacturer’s specifications, and
in accordance with industry guidelines.
5. Stage Drapery
a. Curtain fabric of professional grade fabric intended for stage use. If not inherently flame
retardant, curtain fabric shall be chemically flame proofed at the mill using an immersion
process. Flame proofing certificates for all fabrics used shall be furnished to the owner
with the as-built drawings.
b. Sew tags identifying manufacturer and size of panel at each end of webbing at top and at
one corner at hem in each drape.
c. Curtains must be constructed with vertical seams unless otherwise specified. The fabric
grain shall run nap down and match in all panels. All panels must be un-spliced along
their height.
d. Construction
(a) Black Poly webbing at 3-1/2” wide shall be double stitched to the top of the curtain with
1” of face fabric turned under the webbing.
(b) Brass rustproof grommets shall be inserted:
(i) at the extreme top corners
(ii) in the pleat centers of curtains sewn with fullness, or
(iii) on 12” centers for flat curtains.
(c) Grommet holes for track mounted curtains shall be supplied with
(i) plated wire “S” hooks, or
(ii) snap hooks, sewn-in at the spacing noted above.
(d) Drapery hung directly from an auxiliary batten shall have a 24” long black cotton tie line
fastened in each grommet hole.
(e) The centerline of the drape shall be marked on the top webbing with “CL” and a white
tie line added to the corresponding grommet.
(f) Curtains sewn with fullness shall have box pleats spaced 12” on center.
(g) Bottom hems shall be 4” wide. These shall be sewn with a separate canvas chain
pocket inside so that the bottom of the canvas pocket rides 2 inches above bottom of
the hem. Provide #8 plated jack chain in the pocket.
(h) All traveling curtains shall be sewn with a minimum 24” of face fabric turned back at the
leading edge. All other vertical hems shall be 2”.
(i) Use mercerized cotton thread, minimum weight of #16, color to match drape fabric.
(j) Labeling
(i) Sew labels onto the back (in most cases, upstage) side of the upper hem at both
ends of each panel.
11 61 62 – Theatrical Lighting Systems
A. Qualifications
1. Where Specialty Theatrical design scope is identified, The A/E design team shall include an
American Society of Theatre Consultants (ASTC) Theatre Consultant with extensive previous
experience in university/college building design environment.
2. The contractor shall place and maintain on the project a sufficient number of skilled installers
who are thoroughly educated and experienced on the necessary crafts and completely familiar
with the specified requirements and methods needed for the proper performance and completion
or the work.
B. Basis of Design
1. Basis of design for Theatrical Lighting System components shall by ETC.
C. Power Systems
1. The Theatrical Lighting system shall provide power distribution for all specialty performance and
architectural lighting fixtures within the envelope of the seating area and stage.
2. The power distribution shall consist of the following:
a. Specialty panel boards utilizing DMX-controlled breakers located panel boards in an
electrical room near the stage.
b. Pipe-mounted receptacle (plug-in) boxes at front-of-house catwalk(s) and side lighting
positions. Plug-in boxes shall incorporate separate receptacle types for switched,
dimmed, or general task lighting loads.
c. Pipe-mounted receptacle raceways mounted to overstage pipe battens. Raceways shall
incorporate separate receptacle types for switched, dimmed, or general task lighting
loads.
d. Wall-mounted plug-in boxes located around the perimeter of the stage at floor level.
Additional plug-in boxes may be provided at designated follow spot operator positions.
e. Floor-mounted plug-in boxes recessed into the stage floor.
D. Lighting Control Network
1. The Theatrical Lighting System shall utilize a dedicated, closed network for control of
performance and architectural lighting. This lighting control network shall not be connected to the
larger campus network, accept at the direction of TCCD’s OneIT department.
2. The lighting control network shall consist of the following:
a. A single wall-mounted equipment rack or NEMA-1 enclosure shall house all network and
architectural control processing components. Locate adjacent to specialty panelboards
for Theatrical Lighting Systems power.
b. A minimum Layer 2 business-grade, managed network switch compatible with all
Theatrical Lighting System control components.
c. DMX node/gateways located variously within the equipment rack or enclosure, at front-
of-house catwalk(s) and side lighting positions, integrated into overstage raceways, and
adjacent to stage and follow spot wall boxes.
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Theatrical Lighting and Rigging Systems Supplement
d. Network receptacle stations located variously at the control booth, any designated
director/rehearsal locations in the seating area, front-of-house catwalk(s), and at the
stage.
e. DMX receptacle stations located in the floor-mounted plug boxes at the stage.
E. Architectural Control System
1. The Theatrical Lighting System shall include control of all architectural lighting fixtures within the
envelope of the seating area and stage.
2. The architectural controls shall consist of the following:
a. Architectural control processor (ACP) capable of snap-shotting DMX values sent over the
lighting control network to create preset “looks” that can be recalled by stations located
through the auditorium and stage.
b. Push-button or key-switched preset stations to control architectural lighting located
adjacent to all entrances into the auditorium and stage.
c. Push-button preset stations to control task lighting located at catwalks located in front of
and over the stage.
d. LCD touchscreen preset station located at the stage. The touchscreen shall be capable
of controlling all performance and architectural lighting fixtures within the envelope of the
auditorium and stage.
e. One (1) portable LCD touchscreen preset station for use throughout the auditorium and
stage.
F. Emergency Lighting
1. The Theatrical Lighting System shall include UL1008 and UL924 equipment to provide egress
lighting during an emergency event.
2. Emergency equipment shall be properly coordinated with Division 26. Provide the following
equipment as required:
a. Emergency lighting transfer switch capable of providing power to all emergency
architectural circuits with the envelope of the seating area and stage.
b. Phase-loss sensor panel capable of triggering emergency control devices.
c. Emergency bypass controller capable of outputting pre-programmed DMX value to all
designated emergency architectural fixtures.
G. Control Console
1. The Theatrical Lighting System shall include a lighting control console capable of operating all
architectural lighting fixtures within the envelope of the Auditorium and stage.
2. The lighting control console shall include the following features and accessories:
a. Network connection capable of receiving/transmitting a minimum of four (4) universes of
DMX values over sACN.
b. Physical encoder wheels for adjusting fixture attributes and intensity levels.
c. Minimum of (20) integrated physical faders for adjusting channels and/or playbacks.
d. Two (2) wide-screen format LCD touchscreens. Reference manufacturer requirements.
e. Wireless remote via an OEM or consumer grade tablet device.
H. Theatrical Lighting Fixtures
1. The Theatrical Lighting System shall include a compliment of high illumination LED portable
lighting fixtures designed for stage applications.
2. All fixtures shall be listed by UL or an OSHA approved Nationally Recognized Testing Laboratory.
3. Fixture types and quantities should include the following:
a. Color-changing LED profile fixtures
(a) Minimum of six (6) color LED engine
(b) Fixture output to meet or exceed 8,000 lumens
(c) Minimum quantity of (40)
b. Color-changing LED wash fixtures
(a) Minimum of six (6) color LED engine
(b) Fixture output to meet or exceed 6,000 lumens
(c) Minimum quantity of (20)
c. Color-changing LED cyclorama fixtures
(a) Minimum of four (4) color LED engine
(b) Fixture output to meet or exceed 4,000 lumens
(c) Minimum quantity of (6)
d. LED follow spot
(a) Fixture output to meet or exceed 100 foot candles (fc) at 100’ throw distance
(b) Minimum quantity of (2)
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