Why Safety Cables Are Required

I don't even see a yoke on that fixture! Curious as to what was holding it up in the first place. It almost looks like it would have been a work light like what you see in gymnasiums.
 
Yeah, I agree - looks like a scoop to me too. They're not terrible for cyc's if absolutely nothing else is available, and they make great blackbox houselights.

"Don't worry, I made sure the clamp was super tight."

A common cause of cast iron c-clamp failure is fracturing from over-tightening, so "super-tight" could actually make a bad situation worse. Good for you in not taking that for an answer.
 
Yeah we had a couple at my last job. I just can't see a yoke in the video so I thought it might be hung differently.
 
It looks like it fell from mid-stage and not upstage.

There was a ton of dust on it.

While not the most compelling argument (I've seen mid-stage scoops covered in dust), I am beginning to agree. While bell-shaped and scoop-like, it is missing the provisions for a color frame, and the way the fixture 'rolls' on the floor suggest that there is no yoke on the instrument. I have seen plenty of old scoops with no color frame runners, but they all had yokes. I doubt the fixture fell out of its bracket.

At first I thought it was similar to this instrument:


But it's probably something more like this:
 
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Watching the video, looks more like a building work-light that was probably up there before the theater electrics were even installed. Those things are often supported by the electrical whip, which probably failed. Funny thing is, when you are assessing the condition of the theater lighting system and it's safety, often preexisting building lighting is ignored. Always good to look for anything that may come down, not just parts of the "theater" system.
 
I was supporting a student on top of a rolling A-frame (I was part of the ground crew that rolled her around on it from unit to unit) focusing a light for the first time (Part of a class with shop hours required). We had covered the parts of the fixture and how to do it, but apparently when it couldn't pan and we said to loosen the pan bolt, she loosened instead the C-clamp bolt... Another reason why I say the Pan bolt thumbscrew is THE preferred one to use... Anyway... she apparently wasn't smart enough to realize something was wrong when a lot of loosening didn't seem to help and seconds later the 6x9 came crashing down missing us by a foot. It was then we discovered safety chains hadn't been used. Safety chains are your friends. And there is no such thing as making something Idiot proof. I've learned they just go and make better idiots.
 
Watching the video, looks more like a building work-light that was probably up there before the theater electrics were even installed. Those things are often supported by the electrical whip, which probably failed. Funny thing is, when you are assessing the condition of the theater lighting system and it's safety, often preexisting building lighting is ignored. Always good to look for anything that may come down, not just parts of the "theater" system.

That's what it looks like to me. My guess is that a rigging cue was being executed when something snagged on the light and ripped the whip out of the junction box or the fixture.

I see way too frequently when someone is doing something with rigging and they encounter resistance but persist on pulling the ropes harder to counter the resistance until eventually something gives or after a great deal of getting nowhere, they investigate further and discover what it was they were snagged on.
 
That's what it looks like to me. My guess is that a rigging cue was being executed when something snagged on the light and ripped the whip out of the junction box or the fixture.

I see way too frequently when someone is doing something with rigging and they encounter resistance but persist on pulling the ropes harder to counter the resistance until eventually something gives or after a great deal of getting nowhere, they investigate further and discover what it was they were snagged on.

This brings up another good safety point - whenever you are operating rigging (whether counterweight or electric hoist) and the lineset isn't moving like you expect it to, STOP IMMEDIATELY. Bad things can happen when a lineset gets snagged on other rigging. Most obviously, a snagged lineset can tear lighting instruments, scenic elements, or other objects free from other rigging, bringing them crashing to the deck.

A less obvious kind of failure can occur when a lineset snags on its way in and the fly crew doesn't stop paying out the lift lines or a lineset on its way out snags another lineset and the fly crew keeps hauling on the hand line. If a snagged lineset coming in breaks free of the obstruction with slack in its lift lines, it will free-fall to the limit of the lift lines. The same thing can occur when a lineset on its way out snags another lineset and lifts it above its trim point - when that lineset works free of the moving lineset, it will free-fall back to its trim point. Either way, the shock load on the rigging can easily exceed the tensile strength of the lift lines. As shown in these examples, a 500-pound load free-falling 6 inches can exert the same stress on the lift lines as a static load of several THOUSAND pounds. Even if the lift lines don't break, they can be stressed past their elastic limit (typically about 60% of the breaking strength), which physically deforms the cable so that it will not perform to its rated strength anymore, making replacement necessary.
 
We actually had this happen over the summer. Our main rag has both a traveler track and flies out, the tech on the deck placed the ropes to open the traveller behind a cleat on the wall, and without realizing that this was done the ASM started to fly the main rag out, this is an electric hoist BTW. He go a few feet up and the traveller ropes caught and ended up breaking the straps holding the traveller track to the pipe, bringing half the main down to the deck. Luckily there was no one on the deck at the time!

Since then no piece of fly is operated without at least two people watching it, one from each side (the controls are on one side and someone usually stands in the wings on the other side of the stage), just to make sure that it doesn't happen again!
 
We actually had this happen over the summer. Our main rag has both a traveler track and flies out, the tech on the deck placed the ropes to open the traveller behind a cleat on the wall, and without realizing that this was done the ASM started to fly the main rag out, this is an electric hoist BTW. He go a few feet up and the traveller ropes caught and ended up breaking the straps holding the traveller track to the pipe, bringing half the main down to the deck. Luckily there was no one on the deck at the time!

Since then no piece of fly is operated without at least two people watching it, one from each side (the controls are on one side and someone usually stands in the wings on the other side of the stage), just to make sure that it doesn't happen again!
To make it easier how about placing the pull ropes on the same side as the controls? one person to control the rigging is how I prefer it less likely for something to go wrong.
 
How the rigging was set up ("It's always been done this way, why would we change it?") and blocking of the show. The main rag has to open at the beginning, then close at end of show, it doesn't actually fly out during show. We fly it out for storage between shows (there is a VERY good reason it has to fly out but I don't want to go into details) and for access to stage. Even so it's a good idea to have someone on either side of the stage watching the rigging move in case something happens they can stop it also, there is an e-stop of the wall where the second person stands so they can stop the rig from moving also.

BTW I no longer work for this company so I couldn't make changes even if I wanted too :) Though I do know the Stage Manager for this season pretty well...
 
Nope nothing, it just keeps going till it stops. I wouldn't call his system new either it was installed over 10 years ago, of course with theater rigging in general I guess 10 years is new :)
I do know there are safety items that you can get installed that would do just what you say, but as I said this was installed over 10 years ago.
 
I've always wondered, say a C-clamp fails for one reason or another, and the light is caught by the safety cable, wouldn't a broken chuck of cast iron come falling down anyways?

Yup. The chunk looks something like this...


BrokenClamp.JPG


Snapped a Chinese clamp that had a defect in the casting (air bubble). Safety on the ellipsoidal stopped it from falling. The chunk of clamp hit a house seat and did some minor damage to it. That's why we have someone on the ground to keep people from walking under the lift when we hang instruments.

And for the record, the falling chunk weighed in at 9 ounces on our postage meter. Getting hit by a chunk of falling clamp that weighs over a half pound can certainly ruin someone's day...
 
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The light that fell in the video looks like our work lights. The y are pendant mounted hanging about 10 ft. down from a junction box. In the video you can see the wires, so I am guessing the fixture snapped at the pendant and the wire nuts let loose.

Since mine is original to the building, I better go up and check them......often.
 

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