Project # HE21909.2301.14 100% CD TSU Rhinehart Stage Lighting & Rigging

Issued for Bid & Construction

Stage Rigging and Curtain Systems

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SECTION 11 61 33

STAGE RIGGING AND CURTAIN SYSTEMS

PART 1 GENERAL

1.1 GENERAL CONDITIONS

A. For the sake of brevity these specifications omit phrases such as "(Sub)Contractor shall furnish and install,” "unless otherwise indicated or specified,” etc., but these phrases are nevertheless implied. Mention of materials and operations requires the (Sub)Contractor to furnish and install such materials and perform such operations complete to the satisfaction of the Architect’s Consultant. Exceptions are noted herein or shown on the drawings.

B. No representative of the Owner shall have power to waive the obligations of this contract for the furnishing of good materials or of performing good work, as herein described, in full accordance with the contract documents. The failure of any representative of the Owner to condemn any defective work or materials shall not release the obligation to at once tear out, remove, and properly replace the same at any time prior to final acceptance upon discovery of said defective work or material. When requested, however, the Owner's representative shall observe and accept or reject any material furnished. In the event the material has been accepted once by the Owner's representative, such acceptance shall be binding on the Owner unless it can be clearly shown that such material does not meet the specifications for this work.

C. All equipment and installation shall be the responsibility of a single contractor. This Contractor shall assume complete responsibility for the engineering, fabrication, transportation, and installation of the work in this Section.

D. Field-verify all sizes, measurements and finishes prior to fabrication. Coordinate with scheduled work of other trades. Immediately notify Architect’s Consultant in writing of any discrepancies, conflicts, or omissions prior to the commencement of work or correct the same at Contractor’s expense.

E. All equipment shall be fabricated, manufactured, and installed in accordance with applicable laws, codes, and standards, including:

1. Rigging Manual (published by the Construction Safety Association)

2. Wire Rope Handbook (published by Wire Rope Corporation of America)

3. Wire Rope Users Manual (published by American Iron and Steel Institute)

4. National Electric Code (NEC)

5. American Society of Mechanical Engineers (ASME)

6. American National Standards Institute (ANSI)

7. American Society for Testing and Materials (ASTM)

8. American Institute of Steel Construction (AISC)

9. IEEE (Institute of Electrical and Electronic Engineers)

10. ICEA (Insulated Cable Engineers Association)

11. National Fire Protection Association (NFPA)

12. National Electrical Manufacturers Association (NEMA)

13. Any and all local governmental or other applicable codes.

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F. Where these Specifications call for a higher standard than the above-mentioned rules, the Specifications shall govern.

G. Nothing in these Construction Documents is to be construed to permit work not conforming to applicable Codes.

H. For all requirements not otherwise addressed by this Specification, the work shall be at a minimum compliant with the requirements of ANSI E1.4-1-2022 – Entertainment Technology - Manual Counterweight Rigging Systems and ANSI E1.6-1-2021 – Entertainment Technology – Powered Hoist Systems.

1.2 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Section, apply to work of this section.

B. Refer to Contract Drawings TR series for plans, graphic representations, schedules, and notations showing Stage Rigging System work.

C. Refer to work by other sections including:

1. Structural steel.

2. Painting and finishing.

3. Rough carpentry.

4. General electrical work (Division 26)

5. Fire protection system.

6. Stage lighting system (“E” series drawings)

1.3 DEFINITIONS

A. The term "Contractor" shall mean the contracting entity, also referred to herein as Stage Rigging Contractor or Manufacturer, responsible for the fabrication, assembly, installation, testing, instruction and completion of all work as covered in these Specifications and related Drawings.

B. The terms "General Contractor" is used herein to refer to organizations, individuals, and their representatives as typically defined for construction projects. These terms refer to parties other than the Rigging Contractor ("Contractor").

C. Technical terms unique to stage rigging and related work shall be construed in the following order, in accordance with:

1. Related Drawings.

2. Specifications

3. Relevant usage and definitions of handbooks, guidebooks, or trade group recommendations by manufacturers' associations or professional and engineering societies, such as ASTM, ASME, ASHRAE, etc.

4. Generally recognized theatrical usage

D. Dead load is defined as the weight of the batten, lift lines, connecting hardware, and any permanently installed equipment including electric cable management.

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E. Live load is defined as the load produced by the attachment of portable equipment applied to the batten by the end user but does not include dead loads or environmental loads.

1.4 SCOPE OF WORK

A. Stage Rigging and Curtain Systems will consist of counterweight and motorized rigging in the theatre. Refer to Contract Drawings TR series for plans, graphic representations, schedules, and notations showing Stage Rigging System work.

B. Work under this section shall include the furnishing of all labor, materials, tools, transportation, services, and supervision necessary to complete the installation of the Stage Rigging System, Variable Acoustic Curtains, and other items as herein listed, all as described in these specifications, as illustrated on the drawings, and as directed by the Architect’s Consultant. Any question as to the installation of equipment should be cleared with the Architect’s Consultant prior to installation. Work is comprised of, but not limited to, the following principal items:

1. Verification of dimensions and conditions at the job site,

2. Line sets, arbors, wire rope, battens, hardware, chain, blocks, etc.,

3. Stage curtains,

4. Curtain tracks and accessories,

5. Motorized hoists and control,

6. Wire, conduit, junction boxes and all other electrical components for motorized hoist and control,

7. Installation of all cords and cables supplying electricity or control signal to any equipment supported by equipment furnished under this Section, including cable saddles.

8. Miscellaneous steel for mounting equipment,

9. Miscellaneous components and parts herein specified.

10. Portable and loose equipment

11. Proof of performance testing

C. Furnish and install complete Stage Rigging System with all necessary apparatus, equipment, wiring, etc., required to insure complete systems in excellent working order as specified herein and on the attached diagrams.

D. Consistent with the detailed information contained herein and on the drawings, provide functional and complete overall systems. Verify complete parts lists, the accuracy of the type numbers, and the overall suitability of the equipment to produce complete functional systems coordinated and interfaced with related work.

E. Minor items of equipment needed in order to meet the requirements stated above, even if not specifically mentioned herein or on the drawings, shall be provided in quality equivalent to other conditions on the project with no claim for additional payment.

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F. Coordinate with related work provided under other sections, including but not limited to the following:

1. Fire protection systems

2. Stage lighting system

3. Lighting plugging devices

4. Building structure and catwalks

5. Smoke vents and roof hatches

6. General electrical work

7. Orchestra shell

8. Ductwork

1.5 JOB CONDITIONS

A. Coordinate layout and installation of rigging with other adjacent work, including structural, light fixtures, HVAC equipment, plumbing, and fire-suppression elements.

B. Verify all conditions on job site applicable or pertaining to this work. Coordinate with scheduled work of other trades. Notify Architect’s Consultant in writing of discrepancies, conflicts, or omissions prior to commencement of work or correct the same at Contractor's expense.

C. The drawings show diagrammatically the arbors, sheaves, running lines, controls, etc.

So far as possible the drawings show arrangement of equipment that will fit into the spaces available without interference. If conditions exist at the job site that make it impossible to install work as shown, prepare and submit drawings to the Architect’s Consultant for approval showing how the work may be installed, and, on approval, install the work without additional cost to the Owner.

D. Contractor shall take care not to damage any equipment or to disconnect any wiring other than as required to interface new system. Any contractor-damaged equipment shall be repaired or replaced by the Contractor at no additional cost to the Owner. Return any systems disturbed during work to found condition.

E. Deliver materials to the job site such that they will be protected from damage. Store all materials at building site under cover.

1.6 APPROVED FABRICATORS

A. The hoists, motors, hardware and related components specified herein shall be fabricated by the following:

1. Protech, 3431 N. Bruce St., North Las Vegas, NV 89030 www.protechlv.com

2. Steeldeck Hall Stage Limited, Unit B, 203-207 Manor Road, Erith, Kent

DA8 2AA, UK

www.hallstage.com

3. Texas Scenic Company, 8053 Potranco Rd, San Antonio, Texas, 78251 www.texasscenic.com

4. Thern Stage Equipment, 5712 Industrial Park Rd, Winona, MN 55987 www.https://thernstage.com/

5. Tiffin Scenic Studios, Inc., 146 Riverside Drive, Tiffin, Ohio 44883 www.tiffinscenic.com

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6. Wenger Corp/J. R. Clancy, Inc., 7041 Interstate Island Road, Syracuse, New York, 13209 www.jrclancy.com

7. I Weiss & Sons, 815 Fairview Avenue #10, Fairview, NJ 07022 www.i-weiss.com

B. The draperies and related components specified herein shall be fabricated by the following:

1. I Weiss & Sons, 815 Fairview Avenue #10, Fairview, NJ 07022 www.i-weiss.com

2. J B Martin Corporation, 645 5th Avenue, Suite 400, New York, NY 10022 www.jbmartin.com

3. KM Fabrics, Inc., Box 7379, Branwood Station, Greenville, SC 29610

4. Rose Brand, 4 Emerson Lane, Secaucus, New Jersey 07094 www.rosebrand.com

5. Liba Fabrics, 132 West 36th Street, 6th Floor, New York, New York, 10018 https://libafabrics.com/

6. Stage Decoration & Supplies, Inc., 3519 Associate Drive, Greensboro, NC 27405 www.stagedec.com

7. Syracuse Scenery & Stage Lighting Co., Inc., 101 Monarch Drive, Liverpool,NY,13088 www.syracusescenery.com

8. Texas Scenic Company, 8053 Potranco Rd, San Antonio, Texas, 78251 www.texasscenic.com

9. Tiffin Scenic Studios, Inc., 146 Riverside Drive, Tiffin, Ohio 44883 www.tiffinscenic.com

C. The track, track hardware, and related components specified herein shall be fabricated by the following:

1. Automatic Devices Company, 2121 South 12th Street, Allentown, PA 18103 www.automaticdevices.com

2. Steeldeck Hall Stage Limited, Unit B, 203-207 Manor Road, Erith, Kent

DA82AA,UK

www.hallstage.com

3. Texas Scenic Company, 8053 Potranco Rd, San Antonio, Texas, 78251 www.texasscenic.com

1.7 RIGGING CONTRACTOR QUALIFICATION

A. Qualified rigging contractors shall have been actively engaged in the sales and installation of theatrical rigging systems and equipment for a minimum of five years. In addition, the qualified contractor shall have completed a minimum of three projects of similar scope and magnitude within the last five years. Contractors not demonstrating this minimum experience at the time of bid submission will not be considered qualified to perform the work specified in this section.

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B. Contractor shall employ only experienced stage riggers to direct the installation of work of this Section. A competent supervisor shall be maintained on this Project during the entire installation. The Contractor shall employ a qualified theatre rigger to review installation of the system as it related to attachment to the Theatrical Rigging System and to building structure.

C. All equipment and installation shall be the responsibility of a single contractor. This Contractor shall assume complete responsibility for the engineering, fabrication, transportation, and installation of the work in this Section.

D. Approved contractors may, at their option, arrange for sub-contract field and special shop work to be done by others. Bid submissions must identify such subcontractors and indicate the work they are to do.

E. Approval indicates approval of the manufacturer only and not approval of specific products. The Contractor shall be required to provide equipment that will meet or exceed the intent of these specifications.

1.8 SUBSTITUTIONS

A. Notwithstanding any reference in the specifications to any article, device, product, materials, fixtures, form, or type of construction by name, make, or catalog number, such reference shall be interpreted as establishing a standard of quality and shall not be construed as limiting competition. The Contractor in such cases, may at his option use any article, device, product, material, fixture, form or type of construction which in the judgment of the Architect’s Consultant expressed in writing, is equivalent to that specified.

B. All materials and equipment specified herein have been determined to provide an overall physical appearance and background of proven operation desired by the Owner, and therefore, to establish a standard of quality required for this project. If equipment or material other than that specified is proposed to be furnished, this Contractor shall be required to furnish the Architect’s Consultant with such samples as he requires, the same to be submitted by the Architect’s Consultant to an independent testing laboratory selected by the Owner for tests to determine the actual equality of the proposed substitute items. All costs and charges incurred by these tests shall be borne by the Contractor. Should such tests prove the substitute materials and equipment equal and acceptable, the Contractor shall be so advised. However, the Owner reserves the right to examine, and where necessary, to have additional tests made by the same independent testing laboratory of the actual equipment delivered to the job site to insure that the delivered equipment is equal in fact to that specified. Should such secondary tests prove the equipment is satisfactory, the Owner will pay the cost for such tests. Otherwise, the Contractor shall pay for the test and shall proceed to remove unacceptable equipment from the job site and to provide that specified. The Architect’s Consultant's decision, based on this test, will be final.

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C. The plans and specifications are based on specific equipment, accessories, processes and arrangements as indicated herein. Acceptance of the shop drawing submittal indicates only the acceptance of the manufacturer and quality and assumes that the specific requirements and arrangements are in compliance with the intent of the plans and specifications. The Contractor shall, at no additional cost to the Owner, furnish all accessories, layouts, equipment, etc., and shall perform all work necessary for proper functioning and to fit his substitute items to the intent and arrangement indicated in the specifications.

D. If a substitute system is selected, the Contractor, at no additional cost, shall provide any changes in architectural, electrical, or structural systems required as a result of the alternate system to the Owner. The decision of the Architect’s Consultant as to the compliance of the proposed system based on the submitted data and demonstrated system shall be final.

1.9 SHOP DRAWINGS AND SAMPLES

A. Shop drawings and equipment data sheets shall be submitted to the Architect’s Consultant in accordance with the requirements of these specifications within 90 days after award of the contract. Failure to comply with this 90-day requirement shall be cause for disqualification of the Contractor and cancellation of the contract without cost to the Owner on the basis that the Contractor has not demonstrated the ability or intention to comply with the Contract Documents.

B. Prepare all shop drawings and field changes under the supervision of a professional structural engineer so licensed by the state of the installation. As a courtesy, the first shop drawing submission does not require a Professional Engineer’s stamp. Contractor shall issue a final shop drawing submittal with stamp prior to manufacture. All as-built drawings shall be stamped and certified by professional engineer. Structural Engineer's review shall include, but not be limited to, all elements related to overhead lifting, structural support of elements and all suspended elements provided under this section, including field modifications.

C. Acceptance of submitted equipment shall be obtained prior to equipment purchasing or fabrication. If shop drawings are rejected, correct and resubmit in the manner as specified. All shop drawing information shall be submitted at the same time; no partial submittals will be reviewed. Review is for conformance with design intentions only.

Review does not relieve contractor of responsibility to verify field conditions; nor does it relieve the contractor of responsibility for errors, omissions, or deviations in submittals.

D. The Contractor assumes responsibility for the accuracy of all dimensions and quantities.

E. Shop drawings shall be performed at a scale of not less than 1/4" = 1'-0" for plans and sections and 1" = 1'-0" for details. Drawings and catalogs shall be marked to show the name of project, date, Owner, Architect’s Consultant, Contractor and/or manufacturer and supplier.

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F. Drawings: Submit complete sets of drawings for review in Portable Document Format (PDF). Drawings shall indicate complete details and dimensions of all work to be performed. PDF shall include a Table of contents and bill of materials. Document shall also contain PDF bookmarks to plans, sections and major system details. Include all equipment types and locations, clearances required, guides, chains, linesets, contractor-fabricated equipment and all other details required to describe work to be performed. Shop drawings shall contain at least the following details:

1. Groove details for all sheaves and drums

2. Complete rigging schematics with weights of all equipment

3. Elevations of each rigging and curtain set type

4. Complete hanging/attachment details

5. Complete hardware details

6. Weights of all equipment

7. Schematic diagrams of all electrical work including motorized hoists

8. Manufacturer’s data sheets

9. Indication of all variances from contract drawings

G. Catalog Sheets: Submit copies of catalog data sheets (8-1/2" x 11"), neatly organized in sets with title page, table of contents, space for submittal stamps, and bookmarks between sections. Additional copies of this set of data sheets are required with as-built drawings. Shop drawing submittal shall contain data sheets in proper order with part or model number clearly indicated on all equipment proposed. Provide a complete list of proposed equipment with reference to its corresponding specification section/paragraph number or equipment title. Denote all deviations from specified equipment on the list.

H. Fabric Samples: Submit a minimum of two (2) sets of samples of all curtain materials with full range of colors and patterns available.

I. Finished Curtain Samples: Submit two (2) finished samples of each of curtain type.

Each sample should be approximately 3' x 3' and consist of all details that will be included in the complete finished curtain less the hanging hardware. The traveler sample may have 4" hems (sample only) with specified fullness and other specified features. All other samples shall have specified hems, webbing, grommets, tie line and pipe pocket.

Samples shall include but not limited to:

1. Main Curtain and Valance

2. Travelers

1.10 RECORDS FOR OWNER

A. Drawings: Maintain a full record set of drawings on the job to show the actual installation of the work performed. All as-built drawings shall be stamped and certified by Professional Engineer and reflect field modifications. Submit four (4) hard copy sets of drawings and four (4) USB drives of electronic copy in PDF format showing 'as installed' work to the Architect’s Consultant for initial review. If 'as installed' documents are rejected, correct and resubmit in the manner specified.

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B. Manuals: At the time of project closeout, submit four (4) sets each of the following manuals to the Architect’s Consultant for review. Manuals (8-1/2" x 11") are to be neatly bound and include title page with the name of the project, date, Owner, Architect’s Consultant, Contractor, Contractor and/or Manufacturer and Supplier. The manuals to be supplied are as follows:

1. Operation and Instruction Manual, including:

a) Table of contents

b) Brief description of the operation of each system, (descriptions shall be written such that new personnel may read the manual and be able to set-up and operate the system).

c) Manufacturer's operation instructions for all user-operated equipment.

d) Small scale, clear laminated plan(s) showing the location of all equipment.

2. Maintenance Data Manual, including:

a) Table of contents

b) A list of all equipment supplied by this contract with manufacturer's name, model and part number.

c) A listing of equipment manufacturer's/supplier's addresses for all equipment covered by this contract.

d) All equipment warranties and guarantees including contractor's guarantee. Explain the limits of the warranty, and whom to contact for service, etc.

e) Manufacturer's owner and service manuals on all equipment under this contract.

f) Replacement parts lists of all major items and equipment indicating specific part ordering numbers.

g) Approved shop drawing catalog data sheets.

h) All test results required under these specifications. Videos shall be submitted in DVD format.

i) Any and all other data and/or drawings required during construction.

1.11 TESTS AND OBSERVATIONS

A. The complete job shall be, during and after construction, subject to the following tests and observations:

1. By Architect’s Consultant observations and tests conducted by or for Consultant in Consultant’s presence. Upon notice, Contractor shall furnish not to exceed two (2) persons (one to be the job foreman) and tools to assist for a reasonable amount of time to make such tests and observations as are requested by the Architect’s Consultant.

2. By any Government or local authority.

3. Operation and visual examination of all manual and motorized components.

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4. Contractor shall demonstrate for Architect’s Consultant, full load testing of all motorized sets that suspend loads. Testing shall include full range of travel in all axes of movement, directed by the installed control system.

Test shall include both controlled stop and emergency stop conditions.

Test weight shall be equal to the live load listed on the Drawings.

Contractor shall arrange for delivery, mounting and de-mounting of weight on motorized sets, and removal of test weight from project site.

a) Variable speed sets shall be tested at a minimum of three speeds:

creep, 60%, and maximum specified. Tests shall be performed at each speed for the full range of travel.

b) For all sets, a test with the weight uniformly distributed across all lift lines shall be performed.

c) For ten percent of each set type, but not less than one per type, a test with the weight eccentrically distributed shall be performed.

Test weight shall be equal to the capacity of the set and distributed so that one lift line shall carry the maximum load per lift line as shown in the Drawings.

d) Testing must be video-recorded with audio and submitted with written certification for each set.

e) Motorized curtain sets where the curtains are intended to be easily removable (legs, borders, etc.) shall be tested prior to curtain installation.

f) Motorized curtain line sets where the curtain is intended to be permanently mounted (bi-parting travelers, proscenium reduction curtains, etc.) shall have the required curtain and hardware installed prior to the full load testing.

g) Cable management systems on stage electrics, along with required plug strip, plug box, etc., must be installed and operating normally during the test.

5. Simulated failure test of mechanical over-speed brakes. Test shall be simulated so as not to compromise the integrity of the installed components. Test does not need to be performed on site but must be video-recorded and submitted. In lieu of this test, manufacturer may supply written certification of a successful test of representative samples.

6. Verification and fine-tuning of all hoist limit switch settings (ultimate and normal).

a) Line sets intended for masking curtains shall be tested prior to curtain installation.

B. After completion of installation and preliminary tests by the Contractor, observation of the work shall be performed by the Architect’s Consultant.

1. The Contractor shall certify in writing to the Architect that the work is complete and ready for observation.

2. System commissioning shall be supervised by a knowledgeable representative of the Contractor.

3. In order for the Architect’s Consultant to conduct system commissioning observation, the following elements must be in place:

a) Rigging system must be complete, and curtains installed. See exception for curtains on motorized line sets in paragraph A above.

b) Rigging control system must be operational.

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c) All electrical components must be operating on permanent building power.

d) Preliminary hard limit positions set.

e) Stage electric line sets complete with plug strips, plug boxes, or other distribution devices as required along with complete cable management required for the device(s)

f) Complete access to areas where the rigging systems are installed, including the stage house, control panels, motors, and other system components.

g) Stage floor installation complete.

4. Contractor is to provide any equipment that may be necessary to access system components, including personnel lifts and/or ladders.

5. Contractor shall provide two personnel to operate equipment during commissioning observation. These technicians must be familiar with safe operating procedures for this equipment.

C. The cost of periodic trips to the job site for final observation by the Architect’s Consultant has been provided for in the Architect’s Consultant's contract. The cost of any additional trips to the job site due to delays, omissions, or mistakes by the Contractor shall be borne by the Contractor.

D. The Contractor shall make any adjustments or modifications necessary from the punch list to bring the work into conformance with established Contract requirements and shall then certify that all work is complete and ready for final observation.

1. The Architect’s Consultant will perform a final review to verify punch list completion.

2. A knowledgeable representative of the Contractor must be present for the final review, with crew as required to move system components.

3. Should deficiencies due to faulty equipment or installation require re-inspection after final inspection, all expenses of such re-inspection, including time and travel of the Architects or Architect’s Consultants shall be the responsibility of the Contractor without cost to the Owner.

1.12 DELIVERY, STORAGE, AND HANDLING

A. Do not deliver curtains until spaces to receive them are clean, dry, and ready for their installation. Ship to jobsite only after roughing-in, painting and other finishing work has been completed, installation areas are ready to accept work. If curtains are installed before dust-generating work is complete, curtains shall be appropriately protected from damage.

B. Handle and install materials to avoid damage.

1.13 GUARANTEE

A. All labor and materials provided under this contract, unless otherwise noted, shall be guaranteed for a period of one (1) year following the date of final acceptance of the installation.

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B. The following equipment provided under this contract shall be guaranteed for a period of two (2) years following the date of final acceptance of the installation.

1. Motorized gear/motor/brake assemblies.

2. Motorized hoist control system.

C. All equipment with factory warranties greater than one year shall have their warranties under the Owner's name.

D. All defects occurring in labor or materials within the guarantee period shall be rectified by replacement or repair. Contractor shall, within this guarantee period, be required to answer all service calls within a 24-hour period and repair or replace any faulty item within 48 hours after the initial service call without charge to the Owner.

PART 2 PRODUCTS

2.1 GENERAL

A. All materials shall be new and of first quality.

B. State-of-the-art assurance: No products shall be accepted if they have been discontinued or superseded at the time of shipment. For such items, the manufacturer shall make products of comparable function to the specification available to the project at no additional cost. Should the manufacturer have developed a later model of specified units, the latest developed unit shall be provided without additional cost to the Owner.

Should the manufacturer develop products of comparable function above and beyond the specification of the listed product, the manufacturer may offer the newly developed product for use on the project. The manufacturer shall notify the Architect's Consultant of any developments to the specified products and shall note any change in the requirements of building infrastructure(s) to support the developments. The Architect and Architect's Consultant shall then determine whether upgraded products shall be accepted.

C. All load bearing rigging components shall be rated for overhead lifting; capable of supporting design loads as shown and shall be of, or treated with, corrosion resistant materials. Where not specifically called out in this Section, rope and wire rope shall be selected using a minimum design factor of eight to one, (8:1). All chain, shackles, and other hardware shall be selected using a minimum design factor of five to one, (5:1).

D. Operating parts of all equipment shall be machine finished, and tolerances, finishes, fit, etc., where not specified, shall conform to good trade practices.

E. All items necessary for a complete, operational, and safe system shall be provided, including bolts, nuts, washers, fittings, anchors, supports, hinges, and all other items required for completeness and operational safety. Where not specified elsewhere in this Section, all bolts shall be Grade 5 or better.

F. The rigging products of certain manufacturers are specified by catalog number for establishing a standard of quality. Items equal in quality and performance by manufacturers other than those specified will be permissible upon acceptance by the Architect’s Consultant.

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G. Equipment quantities are "as required" or "as shown on drawings" or "as specified elsewhere" unless otherwise noted.

H. Provide all guards and other protective devices required to ensure protection of individuals who may be near or adjacent to equipment and devices during normal operation.

I. Loading capacity of systems is defined as the live load exclusive of the dead load.

J. Dead load is defined as installed infrastructure such as pipe battens, truss battens, sandbags, hooks, plug strips, etc.

K. Should the Contractor choose to suggest alternate methods that require heavier dead loads, the Contractor shall be responsible for increasing the capacities of the individual components, including the arbor capacities, accordingly. Any alternate methods must be approved specifically by the Architect’s Consultant.

2.2 ENGINEERING RESPONSIBILITY

A. The engineering of all equipment, devices, machinery, and systems shall have the following considerations:

1. Safety to personnel during operation, use, and maintenance.

2. Adequate load supporting capability and fail-safe design.

3. Proper consideration of all systems and elements, including electrical insulation levels, interrupting capacities, protective relays, impact strength, breaking strength, emergency stopping distances, acceleration and decelerations rates, and normal working stress capabilities of equipment and all components.

4. Reliability, with consideration for special or unusual requirements of the unit or installation.

5. Ease of operation and maintenance.

6. System operating sequences, including accounting for simultaneous as well as sequential operation of systems and sub-systems.

7. Coordination with associated and/or adjacent systems provided by others.

8. Quiet operation.

2.3 MISCELLANEOUS COMPONENTS AND SUPPLEMENTAL SUPPORT

A. Additional supplemental support structure not furnished under other sections and other fittings required for installation, support, bracing and/or operation of Stage Rigging System components are the responsibility of this Section. Provide all supplementary support necessary for safe and proper static and dynamic conditions of all systems and components required for the work of the Specifications. All attachments, anchorages, connections, and miscellaneous supplemental support shall be designed, supplied, and installed by the Contractor and reviewed by the Architect’s Consultant.

B. Special components may be required for muling around structural components to meet wire rope fleet angle requirements, supporting hoisting cable, or dropping lines through structure to battens. These special components shall meet or exceed comparable equipment specified herein. Idler blocks, pivot blocks, structural support for these blocks, etc., required to make all lines fully operable, whether such components are specifically named or not, shall be furnished without claim for additional payment.

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C. Additional mounting components, such as miscellaneous steel, wood blocking, and fittings, required for installation, support, bracing, and operation of equipment under this Section shall be provided without claim for additional payment. These components shall be coordinated with other trades.

D. Patented channel type structural steel shall accommodate the required load but shall equal Unistrut Series P1000 at minimum.

E. Flame cutting is not acceptable.

F. Miscellaneous steel shall be of suitable types and sizes. All straps, rods, anchors, clip anchors, clip angles, and other hardware necessary for the attachment shall be supplied.

G. This Contractor shall coordinate these locations and requirements with the General Contractor.

H. All methods of connection and imposed loads resulting from the Contractor’s work shall be submitted to the Architect’s Consultant prior to fabrication.

2.4 WIRE ROPE

A. Wire rope shall be first quality, galvanized carbon steel, and impregnated with a dry lubricant. All cable ends shall be neat, seized and smoothed to prevent scratching and catching. Wire rope shall be terminated with cable thimbles and utilize one of the following termination methods:

1. Nicopress oval copper sleeves properly sized for the wire rope as manufactured by National Telephone Supply, applied in conformity with manufacturer's instructions. Nicopress stop sleeves shall be copper as manufactured by National Telephone Supply.

2. Forged wire rope clips as manufactured by The Crosby Group, Inc.

(Crosby® Clips), applied in conformity with manufacturer's instructions.

B. Wire Rope Diameter:

1. Standard Rigging – 1/4"

2. Motorized Rigging – 3/8”

3. Fire Curtain Hoist – 1/4"

4. Fire Curtain Guide – 1/4"

C. Approved Equipment:

1. Hoist and Rigging – Macwhyte 7 x 19 Utility Cable

2. Guide – Macwhyte 7 x 7 Non-Flexible Utility Strand

2.5 HOIST LINE TERMINATION ASSEMBLIES - WIRE ROPE

A. Batten connection:

1. Type 1 – Wire rope shall be terminated as specified elsewhere or as shown on drawings and fitted with 36" long trim chain. Trim chain shall be connected through the cable thimble and terminated as specified elsewhere. Chain shall make at least one full wrap around the pipe batten.

Type 1 terminations will be installed on all single batten linesets unless otherwise noted

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2. Type 2 – Wire rope shall be as specified elsewhere or as shown on drawings and fitted with rated jaw-jaw turnbuckles. Type 2 terminations will be installed on all double batten linesets unless otherwise noted.

2.6 BATTENS

A. Pipe battens shall be nominal 1 ½" black steel pipe (1.9” O.D.) ASTM A53/A Strong (Schedule 40), stripped and painted with at least one coat of black primer and one coat of flat black paint free of surface irregularities, in lengths as indicated on rigging schedule.

B. Splices shall be close-fitting internal steel sleeves with a wall thickness of not less than

0.1875 inch, and min. 24 inches long. Both sides of the splice shall be held in place with a minimum of two (2) plug welds per side. Splices may also be bolted with two bolts evenly spaced on each side of the splice. Bolts shall be oriented 90° off access from adjacent bolts. Bolt length shall not extend more than three threads beyond the properly tightened nut.

C. Battens shall be engineered and installed for straight installation.

D. All battens shall have bright yellow end caps on each end for visibility in the loft. End caps shall be a minimum of 6” long and provide a smooth surface to the batten end. Line set number shall be stenciled on each end of each batten inside of the end caps, in contrasting color paint, such that the number is readable from the floor when the pipe is flown out and from position upstage of the batten when the pipe is flown in. In lieu of end caps, battens can be painted for 24” on each end with bright yellow enamel.

E. Paint on every batten a 1” wide strip at center stage of the batten.

2.7 TURNBUCKLES

A. General

1. Turnbuckles shall be drop forged and galvanized, and conform to ASTM

F-1145 Type 1, Grade 1 standard.

2. Turnbuckles shall be moused after adjustment to prevent loosening.

2.8 BATTEN PIPE CLAMPS

A. Full Pipe Clamps:

1. Pipe clamps shall be made of two strips of 12 Ga. (2.780 mm) by 2 inch

(50.8 mm) hot rolled steel formed to encompass and clamp the pipe batten to prevent its rotation. Corners shall be rounded.

2. There shall be a 3/8 inch x 1 inch (9.525 mm x 25.4 mm) hex bolt with lock nut above and below the batten. A 5/8 inch (15.875 mm) hole in the top of each clamp half allows the attachment of cable, chain, or other fittings.

3. Full pipe clamps shall have a manufacturer's rated working load limit of at least 1400 lbs.

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2.9 MOTORIZED RIGGING COMPONENTS

A. All motors, hoisting cables, chain, sheaves, hardware, etc., shall be rated for overhead lifting; capable of supporting design loads as shown and shall be of, or treated with, corrosion resistant materials.

B. Motors

1. General

a) All motors shall be properly sized for the application and not more than 1.25 times the combined live load and dead load at the specified speed.

b) Motors shall be totally enclosed and fan cooled.

c) Except as otherwise specified, all motors shall have minimum

Class A winding insulation in accordance with current NEMA Standard MG 1-12.40 rated for 15 to 20 minute intermittent duty cycle.

d) All motors shall be equipped with sealed bearings.

e) Conduit connection box shall be watertight, of cast iron, aluminum, or wrought iron construction, with neoprene gasket. A tapped hole shall be provided for conduit entrance and connection box shall be oriented and coordinated with associated equipment to provide full access to internal connections. Corrosion resistant, high melting point, non-flammable sealing compound shall be used around motor leads where they pass through the motor frame.

2. AC Motors

a) All AC motors shall be squirrel-cage type, of NEMA torque design

B, with medium starting torque, normal breakdown torque, low slip, and low starting current.

b) All AC motors shall be TEFC (totally enclosed, fan cooled) enclosures as defined by NEMA Standard MG 1-12.21.

3. DC Motors

a) DC motors shall be variable speed TENV (totally enclosed, non-ventilated) and designed for continuous duty cycle.

b) Units shall be equipped with integral tachometer units for speed regulation feedback to the associated drive electronics. Use of armature voltage feedback for speed regulation shall not be permitted. Tachometer output shall be coordinated with the drive amplifier provided.

c) Units shall incorporate an internally mounted winding thermostat to monitor winding temperature. This thermostat shall interrupt the control circuitry to the associated drive in such a fashion so as to prevent operation when safe operating temperatures are exceeded within the motor.

d) Units shall have class H+ insulation on armature and field windings and shall conform to a class F maximum temperature rise curve. All DC motors shall be specifically designed for operation in conjunction with controlled phase rectified power amplifiers.

e) DC motors shall be selected with sufficient de-rating and regard for field heating due to site environmental conditions.

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4. For all fixed speed winches, the gear reducer shall incorporate a high inertia flywheel at the motor stage for "soft start" and "soft stop" capability.

C. Gear Reducers

1. General

a) The output shaft shall be supported by two tapered roller bearings.

The gears shall run in an oil bath. The shaft bearings shall be provided with double lip oil seals to prevent leakage.

b) Two (2) removable, threaded lubrication plugs shall be furnished for each gearbox. Upper plug opening shall be for lubricant entrance, and lower plug opening shall permit simultaneous purging of spent lubricant from the bearing.

c) Provide a drain plug in the bottom of the frame on the bearing brackets so as to permit periodic drainage of any possible accumulation of moisture.

d) Provide full drip pan under motor and reducer assembly.

2. Right Angle and Helical Bevels

a) Each right angle bevel or spiral bevel gear drive shall be selected to transmit twice required torque, horsepower, and impact. All ratings shall be AGMA mechanical ratings for load classification service factor equal to 2.0, except as otherwise noted.

b) Each right angle bevel gear drive unit shall consist of the following:

c) One housing made of high tensile nickel cast iron, properly reinforced at all strain points for maximum rigidity, with precisely located gear set bearing supports. Each housing shall have sufficient capacity for lubricant, and surface area for adequate heat dissipation.

1) Pinions, gears, and gear shafts manufactured from chromium, molybdenum alloy steel (AISI C-4150) and heat-treated to 32 Rockwell "C" scale minimum core hardness.

2) Pinion and gear shafts supported by tapered roller or precision ball bearings of adequate capacity, properly mounted, and furnished with oil seals.

3) All shaft diameters precisely ground, stepped, and radiused to minimize stress concentrations.

3. Helical Worm

a) Gear reducers shall be combination helical-worm reducer, directly flange-mounted to the motor/brake assembly. The reducer shall have two (2) gear stages; the first stage shall be helical, and the second stage shall consist of a worm and worm wheel. The worm shaft shall be milled, hardened, and ground to insure maximum efficiency and long life.

b) Gear reducers shall be enclosed in high-strength gray cast iron housings with precisely located gear set bearing supports. Each housing shall have sufficient capacity for lubricant, and surface area for adequate heat dissipation.

c) Gear reducer shall incorporate a high inertia flywheel at the motor stage for "soft start" and "soft stop" capability.

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d) Gear reducers shall be SEW-Eurodrive "Helical-Worm Gear” or approved equal.

e) Gear reducers shall be of the worm gear type with compound helical bevel to single envelopment worm or double enveloping worm gears. Single stage 'Spirol' gearing is not acceptable equipment provided for the Work of this Specification.

f) Worm gear reducers shall be selected to safely transmit specified torque and horsepower. Capacity and type shall be as required.

Design of the power transmission train shall provide for gearing ratios of the worm gear stage to be greater than 40:1 wherever practical. Ratios less than 40:1 shall require approval of the Architect’s Consultant. All ratings shall be AGMA Class 2 mechanical ratings with a load classification service factor equal to 1.3, except as otherwise noted or approved.

g) Each worm gear reducer shall consist of essentially the following:

1) One housing made of high tensile nickel cast iron, properly reinforced at all strain points for maximum rigidity, with precisely located gear set bearing supports.

Each housing shall have sufficient capacity for lubricant, and surface area for adequate heat dissipation.

2) Worm gears manufactured from gear bronze with minimum tensile strength of 40,000 PSI and properly keyed or splined to the gear shaft. Gear shafts shall be manufactured from chromium, molybdenum alloy steel

(AISI C-4150).

3) Worm and worm shaft manufactured from chromium, molybdenum alloy steel (AISI C-4150) and heat- treated to 32 Rockwell "C" scale minimum core hardness.

4) Each worm gear and shaft supported by two (2) tapered roller bearings of adequate capacity, properly mounted, and furnished with oil seals.

5) All shaft diameters precisely ground, stepped, and radiused to minimize stress concentrations.

D. Primary Brake

1. Automatic power failure braking shall provide fail-safe stopping in the event of power loss.

2. Except where indicated otherwise, all brakes shall operate from single-phase AC, and shall be electrically released/spring applied, designed to conform to applicable NEMA standards for intermittent duty.

All brakes shall be furnished with means for manual release.

3. Brakes shall have drip-tight NEMA type 2 enclosures.

4. All brakes shall stop and hold a minimum of 200% of motor full torque capacity.

5. Any required brake conditioning (for example burn-in) shall be completed prior to system commissioning.

6. Brake noise shall comply with the noise requirement as outlined in this specification.

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E. Secondary brakes

1. All motors shall incorporate one of the secondary brake methods described below.

a) Centrifugal overspeed

1) Brakes shall be a fully mechanical overspeed brakes, directly mounted to the drum shaft or sprocket drive shaft.

2) The overspeed brake shall engage automatically when the set exceeds the maximum specified speed by 10%.

3) It shall be possible to preset the brake tension to adjust the stopping distance, so that it brings the load to a controlled stop without shock.

4) The secondary brake shall stop and hold 200% of the full load torque.

b) Pneumatic-release disk brakes

1) Brakes shall be spring-applied, pneumatically released disk brakes, directly mounted to the sprocket drive shaft in two (2) locations.

2) The brakes shall engage automatically when the set exceeds the maximum specified speed by 10%, E-stop is engaged, or the control system detects a fault.

3) Each secondary brake shall stop and hold 130% of the full load torque.

c) Drive-through brakes

1) The brake shall be a continuously applied, automatic load brake with a retarding torque matching the load on the hoist.

2) The brake shall be selected and designed to accommodate the heat produced during normal operation without undue wear.

d) Redundant gear/motor/brake assemblies

1) When redundant gear/motor/brake assemblies are used as the secondary braking mechanism, at least two assemblies shall be required to move to the load, while any one shall be able to stop and hold the full torque load.

2) The gear/motor/brake assemblies shall be located on the extents of the drive train so that either gear/motor/brake can stop and hold the full load.

3) The brakes shall engage automatically when the load exceeds the maximum specified speed by 10%, E-stop is engaged or the control system detects a fault.

2. A redundant motor brake on a single motor shaft shall not be used as a secondary brake.

3. The secondary brake shall not apply more than 300% of the full load torque to the system.

4. Any required brake conditioning (for example burn-in) shall be completed prior to system commissioning.

5. Brake noise shall comply with the noise requirement as outlined in this specification.

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F. Frames & Guards

1. All motors and associated gearboxes shall be installed on built-up frames, which contain all elements of the lifting system. Frames shall be securely attached to structure.

2. All motor units shall have durable, leak-proof drip pans to contain leakage of oil from motor, gearbox and/or pillow blocks.

3. All exposed moving equipment, devices, and ropes within 7 feet of a working surface shall be guarded in a manner to prevent accidental contact with other machinery, devices, lines, or personnel. Guards shall not impede the operation of the protected device or adjacent devices.

a) Sheaves, drums, shaft assemblies, and ropes moving at the lineset load speed on a hoist limited to no greater than 30 feet per minute and located at the gridiron(s), attic, rigging pit, and catwalks may not require this guarding if both the following conditions are met:

1) “Authorized Personnel Only” signage is provided at access points to these areas, per the Drawings.

2) Clearances are provided around the equipment such that people need not contact components to access any part of the gridiron/catwalk.

b) Guard construction shall be sufficient to resist incidental impact without deforming. When located underfoot, guards shall be capable of supporting a 310 pound person.

1) Guard material for custom assemblies shall be open metal mesh with openings not to exceed 1/2 in. unless otherwise noted in the Drawings.

2) Shrouds for packaged hoists, as engineered by the hoist manufacturer, may act as guards, provided all other…