Theatrical stage counterweight rigging systems are essential to modern stagecraft, allowing scenery, lighting, and curtains to move safely and efficiently. However, behind the stage rigging system lies a machine, and like any machine, it requires regular inspection and maintenance to remain safe. So, how often should you inspect your theatre’s counterweight rigging?
The Industry Standard: Annual Inspections
According to ANSI E1.47-2020, Recommended Guidelines for Entertainment Rigging System Inspections, as well as guidelines from major manufacturers such as H&H Specialties, JR Clancy, ETC, and Thern, as well as legacy manufacturers including Secoa, both manually operated and motorized rigging systems should be inspected annually. In fact, ANSI E1.4-1, which covers manual counterweight systems, also emphasizes the importance of annual inspections, or more frequent inspections as recommended by the manufacturer or local codes.
These annual inspections, commonly referred to as “Level 1 inspections”; focus on accessible components including:
- Battens and pipe weight
- Counterweight arbors
- Rope locks and purchase lines
- Loft blocks, head blocks, and tension blocks
- Signage and load markings
- Logbooks, training records, and flame retardancy documentation
When a Level 2 Inspection Is Needed
Every five years, or any time new equipment is installed, altered, or repaired, a Level 2 inspection is recommended. This more thorough inspection typically requires access equipment such as a lift and allows the inspector to evaluate:
- Grid-level equipment
- Rope terminations
- Out-of-reach sheaves and hardware
- System compliance with original design intent
- System compliance with ANSI Standards
Motorized or automated systems also require Level 2 inspections annually, per ESTA and many manufacturer guidelines. Some manufacturers require a documented annual inspection to honor the warranty.
Generally speaking, we only provide Level 2 inspections.
Who is qualified to inspect
Stage rigging inspections must be completed by a qualified person, someone with at least five years or 10,000 hours of relevant experience, including design, installation, inspection, and functional testing. ANSI E1.47 explicitly excludes operators without rigging maintenance or engineering experience from being considered qualified inspectors. Typically, an ETCP Certified Theater Rigger will meet these requirements; however, it should be noted that ETCP Theater Rigging is an operator’s Certification, not an inspector’s Certification.
Our Inspectors hold ETCP Theatre Rigging Certification. We are based in Missouri, where we are also State of Missouri Certified Safety Consultants. In addition, our owner holds a Master’s degree in Occupational Safety Management and is a certified ETCP Theater Rigger. Our inspectors are also Journeyman in the IATSE Union.
We strongly encourage your inspector to be ETCP Certified regardless of what company you choose to work with.
Why Inspection Frequency Matters
Theatre rigging failures often stem from human error; however, the failure to identify worn, misused, or non-compliant components drastically increases the risk. Without annual inspections:
- You expose performers and technicians to serious hazards.
- Your venue may fall out of compliance with OSHA, IBC, and local fire codes.
- Liability increases; ignorance is not a defense in a courtroom.
- Minor issues often go unresolved until they escalate into expensive problems.
As the H & H Specialties theater rigging manual reminds us, “A counterweight rigging system is a machine… and like any other machine, it requires regular inspection and maintenance.”
Venue-Specific Considerations
Schools, churches, and community centers often overlook rigging maintenance, especially in newly constructed or renovated venues. But even in low-use environments, temperature, humidity, and improper operation can degrade system components. That’s why the age of the system is not a valid reason to skip inspections.
Takeaway: Inspect Annually, No Exceptions
Annual inspections serve as the baseline for ensuring safe, code-compliant theatrical rigging. Combine that with staff training, recordkeeping, and a responsive maintenance plan, and you’re well on your way to creating a safe and functional performance environment.
If your system hasn’t been inspected in the past twelve months, or if no one in your building knows the last time it was, you’re overdue.