Page 1 Stage + Backdrop Manual 2016 STAGE & BACKDROP MANUAL STAGE DECK Gloves and safety boots to be worn at all points during construction. Lift pane...
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STAGE & BACKDROP MANUAL
STAGE DECK Gloves and safety boots to be worn at all points during construction. Lift panels between at least 2 people. Equipment: 18 x Deck panels, 72 x leg tubes 30 x T-shaped deck levellers 28 x Deck clamps 2 x 2400mm tubes 6 x Doughty 90 deg fixed couplers
1. Turn deck panels upside down and insert legs into corner clamps. Close clamp firmly onto legs. Ensure each leg is fully inserted before locking in place.
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Stage + Backdrop Manual 2016
2. Identify 4 x decks with handrail fixing holes, these are placed in pairs on either side of the stage. Refer to layout drawing.
3. Locate correct position of the stage setting out and the corner positions 4. Starting with the decks that have hand rail fixing holes, move decks into upright positions on the floor without dragging their legs across the floor. Take care to lift panels when moving so as to not scrape legs on the floor. 5. Use 1 x T-shaped deck leveller between each connecting panel edge. Usually located in the middle of the deck edge. Use 26 x T-shaped deck levellers for this step. 6. Add an extra T-shaped deck leveller to each side panel with hand rails and the front corner decks above the tube holding the lighting stand firmly in place. Use 4 x T-shaped deck levellers for this step. Refer to layout drawing. 7. Fit all 28 x deck clamps from underneath to each joint between deck panels and tighten using the wing nuts installed. Hand-tighten, but firmly.
8. Fit lighting-stand stabiliser tubes (2 x 2400mm) to inside of rear legs to the front corner stage decks using 3 x Doughty 90 deg fixed coupler clamps for each tube. Refer to layout drawing.
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Stage + Backdrop Manual 2016
CARPET Equipment: Three rolls of double sided NEC rated carpet tape Carpet 10m x 4m Do not remove the plastic protective coating on the carpet until the very end Sharp retractable knives ('Stanley' type), with carpet-fitter blades to prevent damage to the aluminium edging of the stage deck. 1. Stick the double sided tape down around the edges of each deck panel. Do not remove the tape backing at this time. The tape may need to be pressed down using the back of a knife.
2. Roll out carpet, protective layer up. Carpet roll is 4m wide and 10m long. This should cover the whole stage with no trimming needed at the front or the far ends.
3. Position carpet over the stage. 4. To stick the carpet down, roll back the carpet from one side to the middle and remove the tape backing. 5. Unroll to stick and repeat on other side. Ensure no ripples are left visible as the carpet is laid. 6. Trim all edges flush to the edge of the stage deck.
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Stage + Backdrop Manual 2016
LIGHTING STANDS Equipment: 2 x LW 155R Lighting Stands 1. Lighting department to locate their lighting stands at each corner of the stage. Care should be taken to ensure the positioning is correct. Please refer to drawings and photographs.
2. Once the stands are located and levelled, push the 2400mm tube tightly down onto the rear outrigger and clamp firmly to the stage leg. Tighten the other two couplers to the stage legs and repeat both sides.
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Stage + Backdrop Manual 2016
HANDRAIL + STEPS Equipment: Sharp retractable knives ('Stanley' type) with standard blades 10 x Spigots with M12 bolts 19mm spanner 17mm spanner 20 x HD 300mm cable ties SMCTATT07 6 x 1m lengths with Velcro. Curtain material (2 x 5m lengths) SMCTATT07 2 x 1m without Velcro labelled ‘STAIR NOSING’ SMCTATT07 2 x 2m with Velcro 1. Cut small slot in the carpet above the holes on the side panels to fit handrail spigots. 2. Fit handrail spigots, screwing down from the top (using 10 x Spigots with M12 bolts and19mm spanner).
3. Fit steps and handrails. Use attached wingnuts and cable ties and 17mm spanner.
PLEASE NOTE: This picture is to show positioning of the cable ties. The nosing shown here is INCORRECT. The item labelled “Stair Nosing” should be used instead. (1m length with NO Velcro)
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Stage + Backdrop Manual 2016
4. Fit side and front corner aluminium edging by slotting into the deck channel edge. Attach short curtains to the channel with the Velcro strips already attached. Use SMCTATT07 6 x 1m lengths with Velcro strips and curtain material 2 x 5m lengths.
5. Use one length of aluminium edging to form nosing at top step either side. This will prevent a trip hazard on the top step. Use SMCTATT07 1m strip without Velcro. DO NOT CUT THE STRIPS. Use 2 x 2m strip with Velcro for side of stage alongside steps. 1 for each set of steps.
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Stage + Backdrop Manual 2016
FRONT PANEL Equipment: 8 x1000mm lengths of unistrut 16 x M10 top hat washers 16 x M10 30mm hex head bolts 32 x M8 bolts 12mm 32 x penny washers 70 x HD 300mm cable ties 4 x H30L-L200 Prolyte ladder truss
1.
Locate the first 1m x 2.4m panel and bolt the short horizontal unistrut to the end of the panel. Use: 4 x M8 bolts 12mm 4 x M8 penny washers. 2 x Unistrut sections 500mm
2.
Locate the 750mm lengths of unistrut and bolt horizontally to the other end of the panel. Half the length should overhang. Use: 4 x M8 12mm bolts 4 x M8 penny washers 2 x Unistrut sections 750mm
3.
Fix the 1000mm lengths of unistrut vertically by bolting to the horizontal unistruts using M10 top hat washers and M10 x 35mm hex head bolts. Channel nuts should already be located in the unistrut. Use: 2 x 1000mm lengths of unistrut 4 x M10 top hat washers 4 x M10 35mm hex head bolts per panel 4 x M10 short spring channel nuts
4.
Lay the 2.0m ladder truss along the floor and cable tie to the stage front legs. Use 1 x H30L-L200 and 20 x 300mm HD Cable ties.
5.
Lean first 1m front panel onto the stage front.
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6.
Locate next panel and bolt through the protruding horizontal unistrut into the T-nuts on the back of the next panel using 4 x M8 bolts and penny washers. Bolt next protruding horizontal length of unistrut to the other end of the panel using 4 x M8 bolts and penny washers.
7.
Bolt 1000mm lengths of unistrut vertically to horizontal unistrut using M10 top hat washers and M10 x 35mm hex head bolts. Channel nuts should already be located in the unistrut. Slide to suit position.
8.
Repeat above steps until all panels are located and bolted together with a 50mm gap below and a 25mm gap behind to the stage deck. Ensure level and line.
9.
Securely cable tie through the vertical unistrut back to the stage legs and the ladder truss laid on the floor. Use 50 x 300mm HD cable ties.
10. Slide convention theme printed sheets into the channels located top and bottom of the panels. 11. Add pedestrian barrier around lighting stand outriggers.
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Stage + Backdrop Manual 2016
BACKDROP FRAME Prolyte Equipment:
BACKDROP TRUSS LIST Quantity
Reference Code
Maker
CCS6-600 CCS6-603
Description Prolyte CCS6 conical coupler for 30/40 series truss Prolyte CCS6 spigot
24 96 96
CCS6-605
Prolyte CCS6 safety 'R' Spring
Prolyte
8
CCS6-S35
Prolyte CCS6 spacer, 35mm
Prolyte
16
CCS6-S50
Prolyte CCS6 spacer, 50mm
Prolyte
3
H30L-C003F
Prolyte Ladder H30 series truss corner, 2-way 90 degrees (ladder flat)
Prolyte
2
H30L-C003U
Prolyte Ladder H30 series truss corner, 2-way 90 degrees (ladder up)
Prolyte
1
H30L-C016U
3
H30L-C017U
3
H30L-L050
Prolyte Ladder H30 series truss corner, 4-way cross (ladder up) Prolyte Ladder H30 series truss corner, 3-way 'T' (ladder up) Prolyte Ladder H30 series truss, Length=50cm
H30L-L075
Prolyte Ladder Length=75cm
H30
4
H30L-L200
Prolyte Ladder Length=200cm
H30
7
series
Prolyte Prolyte
Prolyte Prolyte Prolyte
truss, Prolyte
series
truss, Prolyte
10
Doughty 90 degree fixed couplers
Doughty
2
Doughty swivel couplers
Doughty
Hard hats to be worn from now on. 3 x copper faced or polyester faced hammers should be included in the kit. Only these types of hammers should be used on aluminium fittings. Coloured tape on the Prolyte truss pieces is to aid positioning of clamps. Page 9
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1. Locate and lay out all backdrop truss materials. (Shown on the stage for clarity only. This procedure should take place off the stage to protect the carpet.)
2. Sort out vertical beams and corner pieces. Note the numbering and labelling system and make sure the parts are in their correct position and the beam is the correct way up to suit the node points shown on the drawing. Please note: The drawing shows the correct ways to locate the diagonals on the ladder truss. Please follow this ‘lacing’ pattern and not necessarily the photographs which are provided as a guide only. All diagonals should follow the ‘lacing pattern from section to section, with the exception of the 3no. horizontals that sit on the floor and go below the stage. These should appear ‘upside down’.
3. Assemble 3 x H30L-L200 2000mm long ladder beams that go under stage deck, (one at each end and one in the centre) with the H30L-C003F Corner pieces. Use the correct conical couplers with taper pins and safety clips. Insert taper pins so that the hole for R Clip is at 90deg to frame (To allow easy access for removal of R clip).
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Stage + Backdrop Manual
4. Attach the 2 outer beams to the inside of the legs of stage. Clamp tightly to 3 stage legs with Doughty 90 deg fixed couplers, but loose to the frame for future adjustment. Use 3 x Doughty 90 deg fixed couplers on each beam.
5. Attach the central beam between the two middle deck panel legs. Clamp in place using “lower centre bracing pole” x 2, 4 x Doughty 90 deg fixed couplers and 2 x Doughty swivel clamps (3 clamps per pole). Refer to detailed drawing.
6. Attach the 500mm Truss sections vertically into each of the 3 x corner pieces. Ensure the bracing pattern continues correctly as per the drawing. The photos here are incorrect. Use 3 x H30L-L050 – one for each corner piece.
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Stage + Backdrop Manual
7. The vertical section of ladder truss should be set 50mm off the back of the stage deck. This is important to enable the clamps to clear the truss nodes.
8. Insert T-piece in either end facing inwards and fix.
9. Insert centre cross section and fix. 10. Add lower horizontal ladder truss taking into consideration the required spacers. Repeat for other side. For one half: Lower Section From right to left: 500 corner piece (H30L-C003U) 50mm spacer (CCS6-S50) 750 truss (H30L-L075) 50mm spacer (CCS6-S50) 2m truss (H30L-L200) 35mm spacer (CCS6-S35) Centre cross piece
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Stage + Backdrop Manual
11. Add 2nd higher horizontal ladder truss. Repeat position of spacers. Using a T-section to connect to the middle vertical frame. Repeat for other side. For one half: Higher Section From right to left: 500 corner piece (H30L-C003U) 50mm spacer (CCS6-S50) 750 truss (H30L-L075) 50mm spacer (CCS6-S50) 2m truss (H30L-L200) 35mm spacer (CCS6-S35) centre T-piece (H30L-C016U)
12. Check all positions and tighten all clamps and fixings. 13. This section should be pre-assembled. (If not, use the spacings and positions shown on the provided drawing): Install 90⁰ angle brackets and Doughty clamps to both levels of horizontal unistrut: 2 x angle clamps, one on each end on each horizontal unistrut. Use positions marked in tape. Top level angle brackets should be facing down and the bottom level angle brackets facing down.
GLOVES SHOULD BE WORN. 16 x Angle bracket assemblies: 1 angle bracket assembly requires: 1 x Doughty clamp half coupler 1 x M12x30 hex head bolt and 1 x M12 nut Angle bracket 4-hole p-1325 (do13) Connection to unistrut with 1 x M10x20 hex head bolt and 1 x M10 Short Spring channel nut. 8 lengths of Unistrut - 1950mm long with plastic end caps. 8 x M10 top hat washers 8 x M10x35 hex-head bolts.
PLEASE NOTE: During de-construction – please leave the L-shaped brackets and clamps attached to the unistruts as this will help the brothers at the next convention site.
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Stage + Backdrop Manual
14. Attach horizontal Unistrut to horizontal truss supports. Note numbering and labels on each unistrut. Ensure correct positioning so that the clamps line up with the spaces in the ladder truss.
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Stage + Backdrop Manual
BACK PANELS Ensure the stage is clear of all tools and materials and a 1m safety zone is marked at the unprotected front edge. One member of the team to act as a watcher while the team work on the stage to warn of the unprotected edge. Leave protective wrap in place and use clean white gloves. 1.
Arrange wrapped 1m wide back panel for the centre position face down on stage deck. Take care that wooden runners are at the bottom.
2.
Check sprung channel nuts in the vertical Unistrut mounted on the back of the panels are 515mm and 1475mm from the bottom edge of the panels (measuring from underside of timber runner, to centre of channel nut.) Use 4 x M10 short spring channel nuts per panel.
3.
Starting in the dead centre, using two people stand up the centre panel and locate, taking care not to damage or ruck the carpet. Push panel back to the truss support and support in position until fixed and safe.
4. Using a separate team behind the stage, bolt the horizontal unistrut into the vertical unistrut on the back of the panels. Use 4 x M10 Unistrut P4045 HG Z Clips and 8 x M10 x 20mm hexhead bolts, 4 more M10 channel nuts and a 17mm ring spanner. Ensure the centre panel is dead plumb and level. Fix securely. Bolt the lower fixings first from the ground level. Bolt the higher level fixings last. It should be possible for a taller brother to reach the higher fixings from the ground level. However, if it is not possible, use a set of class 1 steps or an approved hop up.
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Stage + Backdrop Manual
NOTE: These clips have been replaced with the Unistrut P4045 Z Clip 4.
Using scissors, cut the plastic wrapping off the centre panel from behind taking care not to mark or damage anything. (It may be possible to leave the wrapping hanging loose over the front until construction is complete to protect the fabric.)
5.
Arrange wrapped back panels for the next two positions either side of the centre panel, face down on the stage deck. Take care that wooden runners are at the bottom.
6.
Repeat Step 2.
7.
Either side of the centre panel, using two people, stand up the next 1m panels and locate, taking care not to damage or ruck the carpet. Push panels back to the truss support and support in position until fixed and safe.
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Stage + Backdrop Manual
8.
From behind slit the plastic wrapping and release from the side about to be jointed. Leave plastic wrapping on the rest of the panel as long as is practical.
9.
Repeat Step 4. Use 16 x Unistrut P4045 HG Z clips, 32 x M10x20 hex-head bolt, step ladder or hop-up and a 17mm ring spanner.
10. Repeat previous steps until 5 x 1m panels are in position. 11. Arrange wrapped 500mm back panels for the two outside positions face down on the stage deck. Take care that wooden runners are at the bottom. 12. Repeat Step 2. 13. Either side of the stage, using two people, stand up the last 500mm panels and locate, taking care not to damage or ruck the carpet. Push panel back to the truss support and support in position until fixed and safe. Fix using method above. Use 16 x Unistrut P4045 HG Z clips, 32 x M10x35 hex-head bolt and an additional 16 M10 channel nuts, a step ladder or hop-up and a 17mm ring spanner.
Now P4045 Z Clips
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Stage + Backdrop Manual
14. Once all panels are in place, check all lines and levels and that all gaps are closed. Tighten all fixings securely, including all fixings to stage legs. DO NOT overtighten. Use 17mm ring spanner and Class A step ladder.
15. Remove protective plastic coating from the carpet and add a line of warning tape 1m from the edge of the stage front. 16. Using clean gloves remove remaining protective wrap from back panels.
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Stage + Backdrop Manual