Codes of Practice for Event Technology - rtl-service.de · Since truss systems are mainly aluminium...

Published by:

VPLT.The Professional Lighting & Sound

Association of Germany

in cooperation with

VBG Verwaltungs-Berufsgenossenschaft

VPLT. SR1.0Codes of Practice for Event Technology

Provision andUse ofTruss Systems2nd revised edition, information correct as at 10th February 2005

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VPLT. · Standard SR1.0 · Truss Systems

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Foreword

This Code of Practice was developed by VPLT’s Truss Systems Working Group („Arbeitskreis Traver-sensysteme“) in collaboration with the Verwaltungs-Berufsgenossenschaft (VBG) (Institution for Statu-tory Accident Insurance and Prevention in the Administrative Sector) and in consultation with the wor-king group of safety engineers from the following TV/radio stations and studios: BR, Bavaria, DR, DW,HR, IRT, MDR, NDR, ORB, ORF, RB, RBT, RTL, SFB, SR, SRT, Studio Hamburg, Studio Babelsberg,SWR, WDR and ZDF.

The purpose of this document is to ensure a uniform level of safety in the provision and use of trusssystems or single trusses and towers (ground supports), taking into consideration customary industrypractice. Therefore, this Code of Practice includes verifiable criteria and characteristics for trusses,their marking, technical documentation, competent use and testing. It also gives an overview of regu-lations to be used and specifies requirements concerning the standard of occupational health and sa-fety.

Important note for English speaking readersThis document is a „Code of Practice“. The German word for „Code of Practice“ is „Standard“. TheGerman word for „Standard“ is „Norm“.

Special thanksThe publishers would like to thank Karl Ruling, Standards Manager of ESTA, for his continuous supporton this publication.


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Contens

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Provision

3.1 Engineering requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Information for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Technical file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.4 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.5 Instructions for use and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Use

4.1 Qualification and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.2 Selection of truss systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.3 Assembly of truss systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.4 Load transmission in truss systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.5 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.6 Ascent and descent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5 Testing

5.1 Test regulations and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.2 Testing prior to product being placed on market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.3 Testing prior to first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.4 Testing during or after assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.5 Periodic testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.6 Testing after substantial changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.7 Removal-from-service criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Annexes

I Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

II Legal Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

III Normative References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

IV Attachment Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

The solutions contained in this booklet do not preclude other, at least equally safe solutions which mayhave been set out in technical rules issued by other member states of the European Union or other sta-tes which are party to the Agreement on the European Economic Area.


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1 Scope

This Code of Practice applies to the provision and use of trusses and truss constructions, which mayinclude ground-support systems or towers, at events.

„Events“ are, for example, concerts, shows, congresses, conferences, exhibitions, presentations, de-monstrations, film or television recordings, etc. The staging facilities for such events include theatres,multi-purpose halls, studios, production facilities for film, television or radio, concert halls, congresscentres, schools, exhibition centres, trade-fair centres, museums, discotheques, amusement parks,sports facilities and open-air theatres.

If truss systems are used in such a way that persons are below them, the requirements and instruc-tions set out in accident-prevention regulation BGV C1 „Veranstaltungs- und Produktionsstätten fürSzenische Darstellung“ („Staging and Production Facilities for the Entertainment Industry“) must beadhered to.

When using truss systems in places of assembly, the respective regulations and laws of the relevantfederal state also have to be observed, e. g. the Ordinance on Places of Assembly („VStättVO“). If atruss system is suitable and intended for repeated re-assembly at varying open-air locations, the „FI-BauR“ regulations for „Fliegende Bauten“ (temporary structures) have to be applied. (See alsoDIN4112 - Temporary structures; code of practice for design and construction).

Notes

Truss systems and ground support systems or towers with flexible or movable elements, as well as sy-stems for moving loads, can be declared machines by the manufacturer in the sense of the MachineryDirective, 98/37/EC.

Such machines must bear a CE mark and have an EC declaration of conformity.

Repeated use and assembly of portable truss systems at the same location or at different locations isnot considered to mean that the product is placed on the market again.

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2 Terminology

For the purposes of this Code of Practice, „trusses“ are multi-chord truss elements made of metallicmaterials. The different lengths of the trusses can be connected by using connection elements (e.g.screws or bolts) as specified by the manufacturer.

Constructions made from trusses („truss systems“) are complex structures, built using special ele-ments such as corners (fixed or flexible), arch elements or a combination of different elements of thesame truss or different truss systems.

Trusses and truss constructions are used to support predominantly static loads or to serve purely de-corative purposes. They can be hung, ground-supported, permanently installed or used as a movingconstruction.


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3 Provision

Only truss systems that meet the requirements stated in 3.1 „Engineering requirements“ are allowed tobe provided. Only connection elements and accessories approved by the manufacturer may be used.

3.1. Engineering requirementsThe calculations for engineering and production of truss systems must be based on the current regula-tions, e.g. laws, ordinances, accident-prevention regulations and technical rules.

Since truss systems are mainly aluminium constructions, DIN 4113, Part 1, „Aluminium constructionsunder predominantly static loading; static analysis and structural design“, DIN 4113, Part 2, „Alumini-um constructions under predominantly static loading; static analysis, structural design and executionof welded constructions“ and the „Richtlinie zum Schweißen von tragenden Bauteilen aus Aluminium“(„Guideline for welding of load-bearing components made of aluminium“, cf. „Ministerialblätter“ mini-sterial gazettes published by the federal states, for example Bayern (Bavaria) MABI 21/1987) are of par-ticular importance.

If other materials are used, the specific standards relating to them must be applied; for example, DIN18800 in the case of truss systems made of steel.

The load capacities of a truss system are determined by the design, the materials used and the me-thod of production. When calculating the permissible loads, relevant engineering practice has to beapplied to all parts of the truss (e.g. the main chords, braces, pipes, wall thicknesses, fasteners,connection elements, weld seams, etc.).

Special engineering requirements:- Usually, aluminium truss elements are welded constructions made of semi-finished parts (pipes, pa-

nels and rods). Often, the semi-finished parts consist of heat-treated wrought aluminium alloys thatlose their strength under the influence of heat. The strength of the weld seams and heat-affected zo-nes, which is inferior to that of the base metal, must be taken into consideration.

- When different alloys are welded together, the data for the weaker metal determines the load-bearingcapacity.

- Any additional bending caused by force-vector eccentricity in the truss nodes and the connectionelements must be taken into consideration.

- It must be taken into account that two elements might be connected at an unfavourable position onthe girder since the user can assemble the elements of the truss system in any combination.

- Misaligned load transmission at the connection points of individual truss elements due to end platescauses local bending.

- Bending due to load transmission, supporting or suspension outside the nodes must be taken intoconsideration.

- Statements relating to normal force, shearing force and bending have to be provided for connectionelements.

- Companies that perform welding work on load-bearing components must be appropriately certified.Aluminium trusses which fall within the scope of building law are subject to, among other regulations,the „Bauregelliste des Deutschen Instituts für Bautechnik“ (the „list of building rules“ drawn up by the„Deutsche Institut für Bautechnik“).

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3.2 Information for useThe manufacturer must produce information for use, as specified in DIN EN 292-2, and supply it alongwith the product.

3.3 Technical fileManufacturers of truss systems must supply a technical file concerning the intended use for each typeof truss they produce. The file must contain the information below.

3.3.1 Technical detailsa) List of all standard system lengthsb) Engineering drawingsc) Self-weightd) Materials used e) List of the approved accessories

3.3.2 Load capacitya) Permissible uniformly distributed loadb) Permissible point load in the field centrec) Permissible point loads at the third points d) Permissible point loads at the quarter points

The mounting position and the support/suspension method must be taken into account when specify-ing the above-mentioned values.

3.3.3 Structural analysis Manufacturers of truss systems must supply with the product evidence that the structural typeanalysis has been approved („approved structural type analysis“), citing the calculation principlesand standards used. In addition, the following details are required:a) permissible normal force (N) in the chord profiles,b) permissible bending (M) andc) permissible shearing force (V).

3.4 MarkingThe following details must be marked on the truss in a permanent, easily visible manner:

a) manufacturer,b) month and year of construction (MMYY),c) type,d) identification number ande) self-weight in kg.

3.5 Instructions for use and assembly The manufacturer must supply instructions for use and assembly, in German, with the product. In particular, the instructions should include the following:

a) details concerning intended use,b) transport instructions,c) handling and procedure during assembly and dismantling,d) instructions on how to correctly assemble system elements,e) attachment instructions (load transmission),f) data on electrical potential equalisation,g) handling and procedure during operation,h) maintenance instructions,i) instructions regarding action to be taken if damage occurs,j) information about procurement of spare parts,k) information about periodic testing andl) details concerning the criteria for removal from service /layoff.


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4 Use

Only truss systems that meet the requirements specified in Section 3, Provision may be used. Trusssystems must be used in accordance with the requirements set out in the following. Truss systems that do not meet the requirements specified in Section 3, Provision must be checked todetermine whether they are suitable for their intended use and, if necessary, derated.

4.1 Qualification and responsibilityThe duties of all persons in positions of responsibility and all persons involved must be clearly defined.The necessary qualifications for planning, assembly and operation depend on the degree of risk invol-ved.

4.1.1 Planning and system selectionPlanning and system selection is usually performed by: an engineer holding a „Diplom“ degree inengineering, a structural engineer, a „Meister“ for event technology or a head rigger (see annex).

4.1.2 Structural analysisThe structural analysis is usually performed by: an engineer holding a „Diplom“ degree in enginee-ring or a structural engineer.

4.1.3 Management and supervisionManagement and supervision during the assembly and operation of truss systems are usuallyperformed by:a „Meister“ for event technology, a head rigger or a light crew chief (see annex).The construction instructions resulting from the planning and approval checks must be on siteduring assembly and adhered to precisely. They must not be changed without the consent of aplanner with one of the qualifications specified in 4.1.1/4.1.2.The person in charge of management and supervision during assembly shall approve the systemfor use. Any transfer to other users should be documented in writing.

4.1.4 MonitoringAssembly and operation of truss systems is usually performed by: an engineer holding a „Diplom“degree in engineering, a „Meister“ for event technology, an event rigging expert with the title„Sachkundiger für Veranstaltungs-Rigging“ (Event Rigging Expert), a head rigger or a light crewchief (see annex).

4.1.5 Attachment of trusses The way in which the trusses are attached (the method of load transmission) is fundamental to thestructure’s load-bearing capacity and stability and may therefore only be performed by appropria-tely qualified persons. Usually, truss attachment is performed by: an event rigging expert with thetitle „Sachkundiger für Veranstaltungs-Rigging“, an event technology specialist with the title„Fachkraft für Veranstaltungstechnik“ or an event operator with the title „Veranstaltungs-Opera-tor“.

Technicians from the trades which use the truss systems do not attach trusses but they do attachappliances and components for their own work (spotlights, loudspeakers etc.) to provided trusseson their own responsibility.

4.1.6 Assembly of trussesTrusses are usually assembled by:personnel who have been given an appropriate briefing.

The system’s elements may be assembled by persons suitable for the job, once they have beenbriefed; however, their work must be inspected by a qualified person upon completion.

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Table: Qualifications and activities involved in the provision and use of truss systems (for informati-on on „Management and supervision“ and „On-site inspection“, see also BGI 810-0, section 2)

4.2 Selection of truss systems Due to the great responsibility involved in planning and assembling load-bearing structures consistingof trusses, it is of particular importance that the truss systems are correctly selected.

The main selection criteria are: - the structural system (e.g. single-span girder or multi-span girder),- the span width between the supports,- main loads (self-weight + carried load) static when system assembled without lifting equipment,- main loads (self-weight + carried load) static and dynamic when system assembled with lifting equip-

ment,- carried loads (for example, wind or snow),- load distribution (point load, uniformly distributed load, area load),- additional loads caused by technicians working on the truss systems and- additional load due to protection against falls from a height („lifelines“).Special structural analysis is necessary for more complex constructions as well as for all load casesthat are not covered by the information for use.

4.3 Assembly of truss systemsTrusses and truss systems may only be assembled by qualified persons (see Section 4.1 „Qualificationand responsibility“).

Assembly may only be performed on the basis of construction instructions and the information for usefor the type of truss concerned.

The stability and the load-bearing capacity must be ensured at all times.

All components used (truss elements, connectors, etc.) must be inspected visually before assembly. Ifany defects are visible, such as plastic deformation or material reduction of the main chords and bra-ces, cracks in or near weld seams, development of slotted holes at connections or the fittings used tosecure them or deformation of connectors, the parts affected must not be installed. They must be mar-ked in such a way that it is impossible to use them by mistake in future.

The truss elements must be assembled in the correct mounting position. When two truss elements areconnected, the diagonal structure must be maintained. Truss elements with vertical end braces can beassembled asymmetrically if evidence is provided that the load-bearing capacity of the structure willnot be weakened as a result.

Planning and Structural Management On-site inspection Attachment Assemblysystem selection analysis and supervision of trusses of trusses

„Diplom“ engineer ✔ ✔ ✔ ✔ ✔ ✔

„Meister“/„Assistent“ for event technology/ ✔ ✔ ✔ ✔ ✔head rigger/light crew chief

„Sachkundiger für Veranstaltungs-Rigging“ ✔ ✔ ✔

„Fachkraft für Veranstaltungstechnik“ ✔ ✔

„Veranstaltungs-Operator“ ✔ ✔

person with appropriate briefing ✔


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Only suitable tools, e.g. plastic-faced or copper hammers, torque spanners, ring and/or open-jawspanners, may be used for assembly.

Electrical potential equalisation for truss systemsTruss systems that might develop dangerous touch voltages in the event of an electrical fault have tobe incorporated into a common potential equalisation system.

This applies to all elements made of electro-conductive material which have equipment placed on orattached to them or across which wires and cables run that, in the event of damage, could make elec-trical contact with metal parts.

The connections can be made with clips, pipe clamps, screw joints or special single-pole lockingconnectors.

The common potential equalisation system must be connected to the earth wire of the electrical powersupply system. (See also section 4.6, BGI 810/SP25. 1/2).

For cable lengths of up to 50 metres, 16 mm2 Cu is considered the standard value for an adequatecross-section. For cable lengths of up to 100 metres, the standard value is 25 mm2 Cu.

In truss tower systems, the potential equalisation connection can be made by means of a potentialequalisation connection point provided by the manufacturer at the tower base. Since the wheels or rol-lers used in tower systems with „sleeve blocks“ insulate the movable part of the truss construction, thelatter must be provided with a separate potential equalisation connection.

4.4 Load transmission in truss systems The term „load transmission“ refers to all the methods and ways in which loads are transmitted to atruss or from the truss to the load-bearing element.

The manner in which loads are transmitted to trusses is a decisive factor in determining the actual loadcapacity of the truss used.

4.4.1 Transmission of net loadsNet loads must be transmitted in accordance with the manufacturer’s instructions.

Where net loads are transmitted, it must be ensured that all loads act vertically and are evenly dis-tributed across the main chords. Loading a truss on one side only can substantially reduce its ra-ted load capacity.

Additional horizontal loading should be avoided because simultaneous combination of verticaland horizontal loads can exceed the permissible stress on the truss. If such additional loadingcannot be avoided, it is essential to ensure that only trusses whose design allows horizontal loadsare used.

Where horizontal and vertical loads occur simultaneously, special structural analysis will be ne-cessary.

4.4.2 Suspension from the load-bearing element There are three basic types of suspension, described below.

a. Direct hitchThis type of suspension uses rigid attachment gear, for example a clamp with a lifting eye, orprofiles with clamps and a lifting eye.

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b. Choked hitchIn this method, round slings are used in pairs. Each sling supports one side of the truss and the twoslings are then both attached to the same shackle or hook.It must be borne in mind, however, that pulling the round slings tight on the upper or lower chord re-duces the permitted load capacity to approximately 80% of the rated load capacity. In other words,using two round slings of the same type only increases the load capacity to a maximum of 1.6 timesthe rated load capacity of a single round sling (depending on the outer angle).

LA x 0,8 2 x LA x 0,8

c. Basket hitchIn this method, the sling is passed below the main chords and/or wrapped around them, or itruns upwards in a straight line on each side of the truss and is then wrapped around the topchords before ending in a shackle or hook.This method improves the slinging factor by approximately 1.4 to 2 times the load capacity(WLL = Working Load Limit) of the sling, depending on its outer angle with the vertical.

LA x 2 LA x 1,4 LA x 1

Outer angles > 60° are not permitted.

Never like this!

The sling must be attached at a node point next to a horizontal cross-brace so that it is able to ab-sorb the compressive force between the main chords.

According to the „Anschlägertabellen“ (load-attachment tables) produced by VMBG (BGI 622) onthe basis of DIN 1492, Parts 1 + 2, LA = load-bearing capacity based on tying method and outerangle to vertical = load capacity factor

0° < � � 45° 45°< � � 60°


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4.4.3 Attachment gearThe term „attachment gear“ refers to all materials and parts which can be used to connect trussesto the load-attachment points. Attachment gear must comply with the specifications laid down inBGV C 1, Section 9 „Load-bearing lines and attachment gear“.

Commonly used types of attachment gear include:

- beam clamps,- clamps with or without lifting eyes,- shackles,- quick-end links with nuts as per DIN 56926,- round slings,- wire ropes,- steel chains and- wedge sockets.

The information provided by the manufacturer regarding the intended use of the different types ofattachment gear must be observed in all cases.

The general rule is that the rated load of attachment gear such as wires and ropes used in anoverhead-suspension application must not exceed one twelfth of the calculated breaking load; forall other types of attachment gear, the maximum load must not exceed half of the load capacityspecified by the manufacturer.

In addition, the expected environmental conditions must also be taken into account when selec-ting attachment gear. The maximum permitted temperature for round slings made of polyester is100° C. Since aluminium conducts heat so well, this temperature can quickly be reached in the vi-cinity of spotlights. In addition, where round slings are used, their weather resistance, particularlytheir UV stability, must be borne in mind. Consequently, when mobile lifting equipment or trussesare attached using ropes or webbings made of natural or synthetic fibres, an additional, tempera-ture-stable safety component (e.g. a wire rope) must be used.

The maximum permissible operating temperature for wire ropes is primarily dependent on theconnection method used. The widely used aluminium ferrule (for turnback wire rope splicing) mustnot get hotter than 100° C. Where the working temperature is hotter, a wire rope with a terminati-on fitted with a Flemish eye must be used.

Only wire ropes fitted with a thimble may be used.

Permissible releasable terminations for wire ropes include, for example, wedge sockets as speci-fied in DIN 15315 or DIN 43148.

Wedge sockets are not permitted to be used in lifting operations.

Load-bearing wire-rope terminations with wire-rope clips of the type specified in DIN 1142 or„frogs“ and „dogs“ are not permitted to be used.

Use of wire ropes with a fixed protective plastic (e.g. nylon) hose is not permitted.

Wire ropes may be fitted with a loose plastic hose in order to protect trusses as long as visual ins-pection of the rope is still possible.

Wire ropes fitted with a loose, protective (often transparent) plastic hose may not be used nearsharp edges if there is no additional protection on said edges.

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4.5 Personal protective equipmentIn the case of work activities where technical or organisational measures are not able to prevent therisk of injury or damage to health, the employer must provide suitable personal protective equipment(PPE) and implements. The insured persons must use said equipment and implements (BGV C 1, Sec-tion 18 (1)).In particular, the following PPE must be provided during the assembly and dismantling of truss sy-stems: safety shoes, gloves, head protection, hearing protection and PPE against falls from a height.

4.6 Ascent and descent

4.6.1 Rope laddersIn principle, rope ladders may be used to ascend onto or descend from trusses, if it is not possi-ble to use ladders, aerial working platforms or scaffolds in the given circumstances. In the field ofevent technology, it is recommended that preference be given to rope ladders made of metal ma-terials.In the case of rope ladders used for work, the height of the ascent/depth of the descent must notexceed 5 m; in the case of rope ladders used for escape or rescue purposes the height/depthmust not exceed 10 m (BGI 638; instruction sheet on rope ladders). Where the height/depth isgreater, rope ladders may only be used in conjunction with personal protective equipment againstfalls from a height. Retractable-type fall arresters („rollersafeties“) of the type specified in DIN EN 341 and DIN EN1496 can be used to secure the ascending/descending person.

4.6.2 Rope-aided ascent and descentThese techniques may only be used by persons with the relevant qualification and experience.

5 Testing5.1 Test regulations and standardsThe regulations and standards to be used for truss testing include DIN 4113 Part 1, E DIN 4113 Part 2and DIN 4112. Truss systems which are used as or which the manufacturer declares to be mechanical equipmentmust be tested on the basis of BGV C1 (GUV 6.15) and BGG 912 (GUV 66.15) in combination with therequirements described in the present section (Section 5).

5.2 Testing prior to product being placed on marketThe manufacturer must ensure that the product is tested prior to being placed on the market.The scope of the testing for truss systems comprises:

a) inspection of the design and production documents, including the structural analysis,b) checks to ensure that the systems correspond to the product documentation andc) inspection of the production facility and the production method.

5.3 Testing prior to first useWhere evidence has been furnished that the manufacturer had testing performed before the productwas placed on the market for the first time, testing prior to first use by the operator/proprietor (i.e.when the equipment is put into operation for the first time) checks whether the equipment is completeand ready for operation.

5.4. Testing during or after assemblyTesting during or after assembly comprises a visual inspection of all parts used and checks to ensurethat the system has been assembled properly. This testing must be performed by a competent person.Particular attention must be paid to the following aspects:

a) deformation (deflection, twisting, etc.),b) damage (cracks, holes, etc.) andc) missing parts (connecting braces/diagonal braces, connectors, etc.)


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5.5. Periodic testingTruss systems are to be tested at intervals, based on the nature and frequency of their use, which allowdefects and damage to be identified in good time. They must be tested at least once a year by a com-petent person. In particular, the testing covers:

a) deformation (deflection, twisting, etc.),b) damage (cracks, holes, etc.),c) missing parts (connecting braces/diagonal braces, connectors, etc.) andd) determination of whether removal from service is necessary.

If the visual inspection raises doubt as to whether the system is free of damage, an additional test me-thod (e.g. dye penetration or ultrasound testing) must be applied to establish further details.

The operator must ensure that the results of the periodic tests are recorded in a test log/file.

(For information on test records, see also BGV C1, section 35)

5.6. Testing after substantial changesTruss systems must be tested by a suitable expert following substantial changes, repairs or where cir-cumstances necessitate.

5.7 Removal-from-service criteriaTruss systems must be removed from service if an assessment of the criteria listed below shows that itis no longer possible to guarantee that they can be safely used for the required period of operation.

5.7.1 Profile structure

a) Reduction of the cross-section due to wear (main chords and connecting braces/diagonal braces)

b) Reduction of the weld-seam thickness due to wear

c) Plastic deformation of the profiles

d) Holes in the profiles

e) Missing profiles or connecting braces/diagonal braces

f) Displacement of the girder profile (truss no longer fits other truss)

g) Cracked weld seams

h) Incorrect repair

i) Corrosion in the profile structure

5.7.2 Connectors and connection elements

a) Erosion and reduction of the cross-section due to connector wear

b) Reduction of the weld-seam thickness due to wear

c) Plastic deformation of the connectors

d) Enlargement of the drill holes

e) Plastic deformation of the connection elements

f) Heavy corrosion in the connectors and connection elements

g) Heavy corrosion between the load-bearing profiles, the connectors and the connection ele-ments

h) Cracked weld seams

i) Incorrect repair


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Annex

I Terminology

II Legal Provisions

III Normative References

IV Attachment Methods


Annex I – Terminology

Technical terms

Attach To connect to the lifting equipment or the load-bearing structure

Chord Longitudinal profile of a truss element

Connecting brace/diagonal brace Diagonally, vertically or horizontally positioned profile

Connection element Loose part for assembling truss elements

Connectors Connection components in a truss element

Corner block Corner/node element for truss constructions

Field centre The point in the middle of two support/suspension points

Framework See illustration

Ground support Elevated truss structure, vertically adjustable or fixed

Hinge section Element of a ground support for erecting/swivelling a tower

Lifeline Horizontal safety rope to which personal protective equipmentagainst falls from a height is attached.

Main chord Longitudinal pipe of a truss element

Plastic deformation Permanent deformation (possibly due to overloading)

Point load Single, undistributed load

Quarter points (QPL) Positions of three loads when dividing the overall length intofour quarters

Semi-finished part Profile (pipe or bar)

Sleeve block Element of a ground support (usually) used to move trusses/rigs vertically

Support/suspension point Position from which a truss is suspended or at which it is sup-ported

Thermal influence Impairment of stability due to welding heat

Third points (TPL) Positions of two loads when dividing the overall length intothree thirds

Tower Vertical truss

Truss Girder assembled from individual truss elements

Truss element A cohesive unit of a truss system

Truss systems See Page 7, section 2, paragraph 2ff.

Uniformly distributed load (UDL) Uniformly distributed load

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Correct framework

Incorrect framework


19

Head und Sleeve Block

Both sides of the lifting equip-ment attached to the truss. Both attachment points are ver-tically beneath the head. No additional horizontal stres-ses or strains.

Attachment with round slingaround the main chord of thesleeve block. This causes bending in thechord.

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Where trusses have fork-end fittings,

each fitting can be used as a hinge.

Main chord

Connecting/diagonal braces

Safety pin

Connector

Connecting pin

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Wheel Head

Chain Hoist

Sleeve Block

Load Bar

Tower Section

Hinge

Chain Hoist Attachement Point

Basement

Outrigger

The entire system is referred toas a „ground support“ (not necessarily with motor-driven vertical extension)

Corner Block

Truss

Rig,consisting of trusses, corner blocks and sleeve blocks

Tower, consisting of wheel head, tower sections and basement


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Legal terms/qualifications

Approved structural type analysis Structural type analysis approved by a certified structural engineer.

Competent person (testing) A competent person for proceeding testings is a person who, by virtueof his or her professional training and experience, has adequate kno-wledge in the field of truss systems and mechanical equipment and isfamiliar with the relevant state occupational health and safety regulati-ons, regulations issued by the institutions for statutory accident insu-rance and prevention („Berufsgenossenschafts“) and rules governinggood engineering practice to such an extent that he or she can assesswhether truss systems and mechanical equipment are safe.

Event operator (IHK) A person who, by virtue of his or her professional training and experi-ence, has adequate knowledge in the field of event technology andhas an „IHK certificate“ qualification (from the Chamber of Industryand Commerce) (see VPLT standard SR3.0).

Event rigging expert (IHK) A person who, by virtue of his or her professional training and experi-ence, has adequate knowledge in the field of event rigging and has an„IHK certificate“ qualification (from the Chamber of Industry and Com-merce - IHK).

Expert (testing) A person who, by virtue of his or her professional training and experi-ence, has special knowledge in the field of safety and mechanicalequipment and is familiar with the relevant state occupational healthand safety regulations, regulations issued by the institutions for statu-tory accident insurance and prevention („Berufsgenossenschafts“)and rules governing good engineering practice. The expert must beable to test the safety of the safety and mechanical equipment andproduce an assessment thereof.

Head rigger Designs truss constructions (not including the structural analysis) andis usually involved in the planning, selects equipment and personneland plans workflows. Due to his or her training, experience and quali-fication („Meister“ for event technology, specialising in stage/studio),the head rigger is able to supervise the rigging work on site and to ap-prove the rigging for use.

Importer (distributor) Importers are the persons or entities who/which introduce technicalwork equipment into the European Economic Area. The law assumes,as it does in the case of manufacturers as well, that the importer is ab-le to assess the safety of the imported technical work equipment.

Light crew chief Designs lighting systems (not including the structural analysis) and isusually involved in the planning, selects equipment and personnel andplans workflows. Due to his or her training, experience and qualificati-on („Meister“ for event technology, specialising in lighting), the lightcrew chief is able to supervise the rigging work on site and to approvethe rigging for use.

Manufacturer The producer of the product, i.e. the person or entity who/which procuresthe materials or pre-manufactured parts and builds a product with them.

Placing into circulation Any making available of technical work equipment to others (users).

Structural type analysis Structural analysis of a truss type.

Temporary structures Temporary structures are structures that are suitable and usually in-tended for repeated assembly and disassembly.

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Annex II – Legal Provisions

Production and designAs a rule, production and design must be based on the state of the art. Existing standards and guideli-nes covering engineering or production requirements must be complied with. Since truss systems aremainly aluminium constructions, DIN 4113, Parts 1 and 2, and the „Richtlinie zum Schweißen von tra-genden Bauteilen aus Aluminium“ („Guideline for welding of load-bearing components made of alumi-nium“) are of particular importance. Steel truss systems are covered by DIN 18800. If other materialsare used, the specific standards relating to them have to be applied.

ApplicationThe accident-prevention regulations issued by the Berufsgenossenschafts (institutions for statutoryaccident insurance and prevention) must be observed at all times.

Building lawStructures which are assembled using modular truss elements and erected outdoors are additionallysubject to building law. If the structures are used on a temporary basis and intended to be repeatedlyassembled and disassembled, they are deemed „temporary structures“. In such cases, a number ofregulations have to be observed and an engineering firm with experience in structural analysis for tem-porary structures should be consulted.

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Annex III – Normative References(No liability can be accepted for the correctness or completeness of the following references)

National

BGV C 1/GUV 6.15 Staging and Production Facilities for the Entertainment Industry

BGI 638 Rope Ladders

BGI 810-0 (SP 25 1/2-0) Television, Radio and Film - Occupational Safety in Production Facilities -Deployment of Qualified Stage/Studio Workers

BGG 912/GUV 66.15 Testing of Safety and Mechanical Equipment in Staging and Production Fa-cilities for the Entertainment Industry

DIN 3088 Steel-wire ropes; rope slings in lifting operations; safety requirements andtesting

DIN 4112 Temporary structures; code of practice for design and construction

DIN 4113-1 Aluminium constructions under predominantly static loading; static analysisand structural design

DIN 4113-1/A1 Aluminium constructions under predominantly static loading – Part 1: Staticanalysis and structural design; Amendment A1

DIN 4113-2 Aluminium constructions under predominantly static loading – Part 2: Staticanalysis, structural design and execution of welded constructions

DIN 5688 Teil 3 Grade 8 chain slings with hook or ring type terminal fittings and endlessslings

DIN 18000-1 Steel structrures; design and construction

DIN 18808 Steel structures; structures made from hollow sections subjected to predo-minantly static loading

DIN EN 818-4 Short link chain for lifting purposes – Safety – Part 4: Chain slings, grade 8

DIN EN 1492-1 Textile slings – Safety – Part 1: Flat woven webbing slings, made of man-made fibres, for general purpose use

DIN EN 1492-2 Textile slings – Safety – Part 2: Roundslings, made of man-made fibres, forgeneral purpose use

EN 287-2 Approval testing of welders - Fusion welding - Part 2: Aluminium and alumi-nium alloys

DIN EN 288-3 Specification and approval of welding procedures for metallic materials -Part 3: Welding procedure tests for the arc welding of steels

DIN EN 288-4 Specification and approval of welding procedures for metallic materials –Part 4: Welding procedure tests for the arc welding of aluminium and its al-loys

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DIN EN 292-1 Safety of machinery; basic concepts, general principles for design; Part 1:Basic terminology, methodology

DIN EN 292-2 Safety of machinery - Basic concepts, general principles for design – Part 2:Technical principles and specifications

DIN EN 353-2 Personal protective equipment against falls from a height - Part 2: Guidedtype fall arresters including a flexible anchor line

DIN EN 360 Personal protective equipment against falls from a height - Retractable typefall arresters

DIN EN 361 Personal protective equipment against falls from a height - Full body harn-esses

DIN EN 363 Personal protective equipment against falls from a height - Fall arrest sy-stems

DIN EN 364 Personal protective equipment against falls from a height; test methods

DIN EN 729-1 Quality requirements for welding - Fusion welding of metallic materials –Part 1: Guidelines for selection and use

DIN EN 729-2 Quality requirements for welding – Fusion welding of metallic materials –Part 2: Comprehensive quality requirements

DIN EN 729-3 Quality requirements for welding – Fusion welding of metallic materials –Part 3: Standard quality requirements

DIN EN 729-4 Quality requirements for welding – Fusion welding of metallic materials –Part 4: Elementary quality requirements

DIN EN 10002-1 Metallic materials – Tensile testing – Part 1: Method of testing at ambienttemperature

ISO 10042 Arc-welded joints in aluminium and its weldable alloys; guidance on qualitylevels for imperfections

International

NEN 2063 Arc welding. Fatigue loaded structures. Calculation of welded joints in unal-loyed and low-alloy steel up to and including Fe 510 (Fe52)

NEN 6710 Regulations for the calculation of building structures

TGB 1990 Design of aluminium structures

BS 7906-2:2000 Lifting equipment for performance, broadcast and similar applications, Part2: Code of practice for use of aluminium and steel trusses and towers

BS 7905-2:2000 Lifting equipment for performance, broadcast and similar applications, Part2: Specifications for design and manufacturing of aluminium and steel trus-ses and towers

ESTA/ANSI E1.1-1999 Entertainment Technology - Construction and Use of Wire Rope Ladders

ESTA/ANSI E1.2-2000 Entertainment Technology - Design, Manufacture and Use of AluminiumTrusses and Towers

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Annex IV – Attachment MethodsThe following illustrations show common attachment methods and how they affect the static stability,the local influences on the truss and the load-bearing capacity of the attachment gear. The illustrationsassume that the truss is used as a single beam with a symmetrical load.

Explanations

Stability: In respect of lateral buckling and unintended movementInfluence: On the trussEffect: On the attachment gear

The following examples refer to Section 4.4.2 a)

Attachment with screwed-in lifting-eye nut/ring bolt

Stability:Horizontal fixing is necessary to ensure lateral stability.Influence on truss:This method does not decrease the truss’ load-bearing capa-city.Effect on attachment gear:This method does not decrease the load-bearing capacity.

Attachment with clamp and lifting-eye nut/ring bolt from above (clamp under tension)

Stability:Horizontal fixing is necessary to ensure lateral stability.Influence on truss:This method does not decrease the truss’ load-bearing capa-city if attached at a node. It can decrease the truss’ load-bea-ring capacity if not attached at a node (local bending of themain chord).Effect on attachment gear:This method does not decrease the load-bearing capacity.

Attachment with clamp and lifting-eye nut/ring bolt from above (clamp under tension)

Stability:No effect on lateral stability.Influence on truss:This method does not decrease the truss’ load-bearing capa-city if attached at a node. It can decrease the truss’ load-bea-ring capacity if not attached at a node (local bending of themain chord).Effect on attachment gear:This method does not decrease the load-bearing capacity.

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Attachment with profile and clamp from below



Stability:The truss must be secured against lateral tilting.Influence on truss:This method does not decrease the truss’ load-bearing capa-city if attached at a node. It can decrease the truss’ load-bea-ring capacity if not attached at a node (local bending of themain chord).Effect on attachment gear:This method does not decrease the load-bearing capacity.


Stability:The truss must be secured against lateral tilting.Influence on truss:This method does not decrease the truss’ load-bearing capa-city if attached at a node. It can decrease the truss’ load-bea-ring capacity if not attached at a node (local bending of themain chord).Effect on attachment gear:This method does not decrease the load-bearing capacity.

Attachment with profile from below


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The following examples refer to Section 4.4.2 c)

Attachment using a round sling

Stability:Horizontal fixing is necessary to ensure lateral stability.Influence on truss:This method does not decrease the truss’ load-bearing capa-city if attached at a node. It can decrease the truss’ load-bea-ring capacity if not attached at a node (local bending of themain chord).Effect on attachment gear:This method does not decrease the load-bearing capacity.

The following examples refer to Section 4.4.2 b)


Stability:No effect on lateral stability.Influence on truss:This method does not decrease the truss’ load-bearing capa-city if attached at a node and if a brace absorbs the compres-sive forces.It does decrease the truss’ load-bearing capacity if not atta-ched at a node or if the compressive forces are not absorbedby a brace (local bending of the main chord).Effect on attachment gear:Decrease in load-bearing capacity due to attachment method:80% choked round sling and outer angle.

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Attachment using a round slingStability:No effect on lateral stability.Influence on truss:This method does not decrease the truss’ load-bearing capa-city if attached at a node and if a brace absorbs the compres-sive forces. It can decrease the truss’ load-bearing capacity ifnot attached at a node or if the compressive forces are not ab-sorbed by a brace (local bending of the main chord).Effect on attachment gear:Decrease in load-bearing capacity due to attachment method:80% choked round sling and outer angle.





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Stability:No effect on lateral stability.Influence on truss:This method does not decrease the truss’ load-bearing capa-city if attached at a node and if a brace absorbs the compres-sive forces. It can decrease the truss’ load-bearing capacity ifnot attached at a node or if the compressive forces are not ab-sorbed by a brace (local bending of the main chord).Effect on attachment gear:With this attachment method, the outer angle has an effect onthe decrease in load-bearing capacity.

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Stability:No effect on lateral stability.Influence on truss:This method does not decrease the truss’ load-bearing capa-city if attached at a node and if a brace absorbs the compres-sive forces. It can decrease the truss’ load-bearing capacity ifnot attached at a node or if the compressive forces are not ab-sorbed by a brace (local bending of the main chord).Effect on attachment gear:With this attachment method, the outer angle has an effect onthe decrease in load-bearing capacity.

VPLT. SR1.0Provision and Use of Truss Systems

2nd revised edition, information correct as at 10th February 2005

Contact:VPLT – Verband für professionelle Licht- und Tontechnik e.V.The Professional Lighting & Sound Association of Germany

Walsroder Straße 15930853 Hannover-Langenhagen

GermanyTelefon +49-511-270 74-74Telefax +49-511-270 74-777

E-mail: [email protected]

www.vplt.org

© copyright by VPLT e.V. 2005

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