16936 STAGE LIGHTING RIGGING (COUNTERWEIGHT) *************************************************************************************************************** SPECIFIER: CSI MasterFormat 2004 number: 11 61 33. *************************************************************************************************************** PART 1 GENERAL 1.1 WORK INCLUDED A. Section Includes: Fabrication, furnishing, delivery, labor, and installation of the stage and lighting rigging system, and all incidental or related items necessary to complete the stage lighting rigging work. 1. Work required for this Section: a. Gridiron, head and loft block beams, and all other structural steel and miscellaneous metals not specifically called out as part of this section. b. Galleries, ladders and catwalks. B. All materials shall be listed by an OSHA approved Nationally Recognized Testing Laboratory (NRTL). 1.2 RELATED SECTIONS: 1. 01043 - Mechanical and Electrical General Requirements. 2. 11062 - Stage Curtains and Tracks. 3. Division 16 - Electrical. 4. 16931 - Stage Control and Lighting Equipment 5. 16937 Stage Lightig Rigging (Pipe Grid). 1.3 REFERENCES A. American Institute of Steel Construction, Inc. (AISC). B. American Society for Testing and Materials (ASTM), latest publications: 1. A36 Specification for Carbon Structural Steel. 2. A47 Specification for Ferritic Malleable Iron Castings. 3. A48 Specification for Gray Iron Castings. 4. A53 Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless. 1.4 SUBMITTALS A. At the A/E's request, submit for review one representative sample of any device or component required under the contract. 1. The components shall be tagged with the name of the project and be shipped to the address specified by the A/E. Project No. SPECIFICATION GUIDELINES 16936-1
2. After review, ship the component to the project for use as a standard. 3. All charges for these shipments shall be identical with the approved component. 4. No component used as a sample will be allowed to be installed on the project. 5. In the event the submissions are disapproved, the components will be returned to the Contractor who shall immediately make a new submission of component meeting the contract requirements. B. Submit shop drawings, for the A/E's acceptance, of a sufficient size to show necessary detail for each component type. Catalog cuts or scale drawings will not be acceptable. C. Shop drawings shall include, but not be limited to: 1. Manufacturer's dimensioned scale drawings showing in complete detail the fabrication of components including finishes, metal thickness, fabrication methods, support methods, method of installation, and other information to show compliance with the Construction Documents. 2. Submit shop drawings and samples of components for approval before fabrication. Details may vary slightly from those shown on Drawings provided the changes to performance or appearance are not altered. 1.5 QUALITY ASSURANCE A. Materials, equipment, appurtenances, and labor provided under this section shall comply with the highest commercial standard and be as specified and as indicated on Drawings. Parts and components not specifically identified or indicated shall be made of materials appropriate for their use or function and resistant to corrosion and thermal and mechanical stress encountered in the normal application and functioning of the components. B. All cast parts, including die-cast members, shall be of uniform quality, free from blow holes, pores, hard spots, shrinkage defects, cracks or other imperfections that affect strength and appearance, or are indicative of inferior metals or alloys. 1. Exterior surfaces that do not receive a finish coat shall be machined, sanded or similarly treated. 2. All finished castings shall be given a minimum of one coat of baked-on clear methacrylate lacquer unless a painted finish is specified. C. Fixtures and components shall be made according to the NEC and bear the UL label. PART 2 PRODUCTS 2.1 EQUIPMENT A. Rigging System: 1. Paint as required under this section shall be the manufacturer's standard finish and color except as noted. 2. Materials shall comply with the ASTM specifications noted in this Sectionr. 3. Materials shall be new, unused and of the latest design. Refurbished materials are not allowed. 4. To establish minimum standards of safety, the following factors shall be used: Project No. SPECIFICATION GUIDELINES 16936-2
a. Cable and fittings: 8.0 Safety Factor. b. Gearmotors: 1.0 Service Factor. c. Cable bending ratio: Sheave is 30 times diameter of cable. d. Tread pressures: 500 lbs. for cast iron, 1000 lbs. for steel. e. Maximum fleet angle: 1-1/2 degrees. f. Steel: 1/5 of yield. g. Bearings: Two times required at full speed for 2000 hrs. 5. Where dimensions and loading capacities have been omitted from this specification, they are to be according to accepted industry standards and the guidelines in this Section. In no way shall the rigging Contractor be relieved of the primary responsibility to provide a safe, fully functional system. 6. The mechanical fabrication and quality of construction shall incorporate best practices for good fit and finish. There shall not be any burrs or sharp edges to cause a hazard nor shall there be any sharp corners accessible to personnel. 7. Moving parts shall have specified tolerances. Sheaves shall run plumb and true and not scrape housings. 8. Equipment shall be built and installed to facilitate future maintenance and replacement. B. Counterweight System: 1. Pipe Battens: Battens shall be 1-1/2" nominal diameter Schedule 40 pipe in lengths as shown on the Drawings. Joints shall be sleeve spliced with 18 inch long sleeves with 9 inches extending into each pipe and held by two 3/8" hex bolts and lock nuts on each side of the joint. a. Manufacturer: J.R. Clancy No.015-67R, 40 ft. long or accepted equivalent. 2. Cable fittings and clips shall conform with wire rope manufacturer's recommendations as to size, number and method of installation. a. Clips shall be drop forged "Crosbys" or malleable as required. b. Pressed sleeve fittings shall be "Nicopress". c. Eyes shall be formed over wire rope thimbles of correct sizes. 3. Lead cables, unless otherwise noted, shall be 1/4" diameter 7 x 19 construction, galvanized aircraft cable with a breaking strength of 7000 pounds. a. Do not use damaged or deformed cables. b. Install wire rope rigging to prevent abrasion of the wire rope against any part of the building construction or other equipment. 4. Trim Chains: a. Trim cables shall be 30 inches long with a snap at one end. b. Chain shall be 2/0, passing link with a 500 pound working load. c. Chains shall be installed on the batten end of each lead line. d. Provide one safety bolt, one nut and two flat washers per trim chain. e. Manufacturer: J.R. Clancy No.015-1192B trim chains or accepted equivalent. Project No. SPECIFICATION GUIDELINES 16936-3
5. Hand Line: a. Hand lines shall be 3/4" first grade Synthetic rope, free of slivers and foreign materials. b. Manufacturer: J.R. Clancy No.028-750SGW, - 3/4" sure grip synthetic rope or accepted equivalent. 6. Counterweight: a. Counterweights shall be 13-3/4" long. b. Each piece shall be free from slab and sharp edges. c. Notch two opposite corners to provide finger holds when loading arbors. d. Provide 80 percent of weight 2 inches thick and 20 percent 1 inch thick for each of balancing. e. Manufacturer: J.R. Clancy B&C Counterweights or accepted equivalent. C. Series Head Block: 1. The diameter sheave shall be made of Class 30 grey iron conforming to ASTM A48, shall have a minimum hub diameter of 3-7/8" and be free of holes and casting flaws. 2. The sheave shall be machine faced and turned with equally pitched grooves for the required number of cables and ropes. a. Groove depths shall be sufficient to encompass fully the cables and ropes. b. Grooves shall be sloped sides (8 degree minimum) and comply with rope and cable manufacturer's standards for groove shape and tolerance. c. The sheave shall be fitted with 1 inch Timken tapered roller bearings, properly sized for the required load and speed. d. The 1 inch diameter machined steel shaft shall be keyed to one side plate to prevent rotation. e. Proper adjustment of the bearing shall be accomplished by means of a fine thread, self-locking nut on the opposite end of the shaft. f. Steel side plates with a minimum thickness of 10 gage shall be shaped to fully protect the sheave and eliminate sharp corners and shall be fillet welded to the base angles. g. Base angles shall be fabricated from 2 inch by 1-1/2" by 1/3" angle with the short leg turned in and notched to clear the cables. h. Each head block shall have at least five spacers, three to be placed to prevent cables from escaping from the sheave grooves. i. Each sheave shall run plumb and true without rubbing its side plates when rotated. 3. Furnish each block with two heavy clips that extend the full block width and have an offset to allow for the flange thickness of the mounting beams. Each clip shall be held rigidly in place by two 3/4" diameter bolts and lock nuts. 4. Manufacturers: J.R. Clancy Series 55 or accepted equivalent with cable groove sand rope groove. D. Series Loft Block: 1. Underhung Loft Block: Project No. SPECIFICATION GUIDELINES 16936-4
a. The 8-1/2" diameter sheave shall be made of Class 30 grey iron conforming to ASTM A48, having a minimum hub diameter of inch and be free of holes and casting flaws. b. The sheave shall be machine faced and turned with the require size rope or cable groove. c. Cable groove depths shall be sufficient to encompass the cable fully and shall have sloped sides. d. Conform rope and cable grooves to rope and cable manufacturer's standards for groove shape and tolerance. e. The sheave shall be fitted with 1/2" diameter ball bearings (1/2" diameter Timken tapered roller bearings), properly sized for the required load and speed. f. The 1/2" diameter steel shaft shall have a dutchman to engage the keyhole in the side plate. g. Accomplish proper adjustment of the bearings shall be accomplished by means of a fine thread, self-locking nut on the opposite end of the shaft. h. The block housing shall have two 10 gage side plates rigidly fastened together with at least three 1/4" bolts and three pipe spacers. i. The housing shall also have a drop forged steel center with a 3/4" threaded end fastened to the side plates by two 5/16" bolts. j. Bolts shall have lock nuts. The center shall be threaded to provide for a 4-inch grip adjustment range for the block mounting. A cut in the side plate shall be made with a 1/2" or 3/4" throat to grip the flange of the mounting beam properly. 2. Fasten the block to the steel beam by means of an angle clip mounted on the threaded end of the center with a 3/4" hex nut. This clip, along with the cuts in the side plates, shall properly grip the lower flange of the beam when the nut is tightened. 3. Manufacturer: J.R.Clancy Series 55 or accepted equivalent with a 1/4" groove. E. Series Mule Block: 1. The 8-1/2" diameter sheave shall be made of Class 30 grey iron conforming to ASTM A48 and free of holes and fasting flaws. 2. The sheave shall be machine-faced and turned with the required size cable groove. 3. Cable groove depths shall be sufficient to encompass fully the cable manufacturer's standards for groove shape and tolerance. 4. The sheave shall be fitted with ball bearings (Timken tapered roller bearings) properly sized for the required load, speed and number of grooves. 5. The steel shaft shall have a dutchman to engage the keyhole in the side plate. 6. Proper adjustment of the bearings shall be accomplished by means of a fine thread, self-locking nut on the opposite end of the shaft. 7. Steel side plates with a minimum thickness of 10 gage shall fully protect the sheave and shall be fillet welded to the base. 8. The base shall be fabricated from two C3/4.1 channels. 9. Each block shall have four spacers placed to prevent cables from escaping the sheave grooves. 10. Each block shall run plumb and true without rubbing its side plates when rotated. 11. The block shall be fastened to the building steel with two full width, 3/4" formed clips with 1/2" bolts and lock nuts. 12. Manufacturer: J.R. Clancy Series 12 or accepted equivalent with five cable grooves for 1/4" diameter cable. Project No. SPECIFICATION GUIDELINES 16936-5
PART 3 EXECUTION 3.1 INSTALLATION A. Hang pipes level (+ 1/8") with the finished stage floor and parallel with the upstage proscenium line (+ 1/4") measured at any point at their length. B. Paint or finish shall be durable flat black except materials at or above grid level, headbeam level and loading rail level. C. Furnish plated or painted turnbuckles, clips, tracks, chains and other items of incidental hardware. D. Comply with ASTM standards noted in Article 1.02 of this section. E. Materials used shall be new, unused and of the latest design. Refurbished materials are not acceptable. F. Burrs, sharp edges or sharp corners are not acceptable. G. Install mule blocks, cable rollers, and guides to provide proper alignment, prevent cable and rope abrasion and to maintain specified fleet angles. H. Shop and field welding shall comply with AISC. Spatter, fissures, craters, or other evidence of poor practice are not acceptable. I. Touch-up finishes disturbed during shipping and installation to match the original finish. J. Cable Terminations, Shackles: Use properly sized and installed Nico-press fittings on all cable terminations. Provide shackles on arbors and other similar terminations for ease of disassembly. END OF SECTION Project No. SPECIFICATION GUIDELINES 16936-6