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Proof Productions built an 85-foot-high “Eiffel Tower” scenic element for the Philadelphia International Festival of the Arts (design by Mimi Lien). Construction and installation presented with a number of challenges.
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Hoists and cranes were not options. The solution was a massive self-climbing truss structure with four vertical ground-supported towers and two moving truss platforms.
“What can be imagined can be built!” This has been the motto of Proof Productions, Inc. since the company was formed in 2002. The “imagined” part often comes in the form of drawings and renderings from a designer. More often than not, these drawings are conceptual or visual in nature and do not include construction details, rigging attachments, structural framing, or electrical schematics. In the case of an automated element, the details can be even more complicated. What looks like a stationary wrought iron gate on paper may be accompanied with the simple instructions requiring the piece mechanically open and close within a fully adjustable time period of 5 – 60 seconds, have DMX control capability, and be rigged to fly.
This is unheard of in the construction and manufacturing industry, where every component is precisely drawn by an architect or mechanical engineer and where very little is left to the experience and ingenuity of the fabricator.
We are pleased to state that things are quite different in our world, the theatrical fabrication industry. That connection between designer drawings and a safe and functional set piece is where some of the magic happens.
Make it fly
That term probably has a hundred different meanings, depending on who is reading it. But it only has one meaning to certified riggers in the rigging industry, and it’s not always a simple request. We are fortunate enough to have just as much experience with on-site rigging and installation as we do with set building. ETCP-certified riggers are also our in-house mechanics. They know that you can’t just bolt a D-ring to the top of a scenic element and call it “rigged to fly.” From the moment a designer’s drawing is evaluated by our team, mechanics are hands-on with design of the framing structure, rigging attachment points, selection of rigging hardware, and weight calculations. Underneath that meticulously painted wood surface is an intentional steel skeleton that is designed to carry the entire weight of the unit to a predetermined amount of rigging points. Consideration is also given to on-site riggers, whether it’s our crew or venue staff, who will need to inspect all critical rigging components. Attachment points and hardware are designed to be accessible and replaceable. Essential framing members are left exposed or are equipped with removable access panels. These are more than just user-friendly features. Proper rigging design is an essential and necessary component in the critical path from conceptual design to installation in the theatre, arena, or event.
In 2012, our company was commissioned to build the “Eiffel Tower” scenic element for the Philadelphia International Festival of the Arts (design by Mimi Lien). Designed at more than 85 feet high, built entirely out of 9,000 lb of steel, and destined for installation in the Grand Atrium of the Kimmel Center, we were presented with a number of challenges. Although the tower would be ground-supported, something of that height is typically assembled with the assistance of a crane. It was determined on a site evaluation that, not only could we not utilize crane equipment due to access limitations into the building, the building did not have adequate roof structure to accommodate overhead lifting via chain hoists. Our solution was to design and fabricate a massive self-climbing truss structure that featured four vertical ground-supported towers and a two moving truss platforms. We designed the scenic tower to be fabricated in layers. Each layer was equipped with structural framing and strategically placed rigging points. The entire 85-foot structure was successfully stack-built, from the ground up, under the supervision of ETCP-certified riggers. The project was made possible as a result of the collaboration between the riggers, mechanics, designers, and fabricators.
Make it move or light it up
Automation and set electrics is often an integral part of set design. From moving features to backlit panels, the fabrication shop is presented with the task of bridging the designer’s vision with the technical components required to create a functioning piece. Automation can require any combination of electric-powered devices including solenoids, gear motors, relays, limit switches, et cetera. Lighting can include a variety of lighting types (LED, halogen, fiber optic) that require a wide range of voltages. Control requirements can range from simple contact closures to more complex DMX and computer control. Our ETCP-certified electricians are hands-on with the entire automation, lighting, and control design process, including the initial concepts (i.e. brainstorming), R&D, and final fabrication. What may be technically complex must ultimately be practical, reliable, safe, and serviceable in the field. The method by which a component ties into house/venue power is just as important as how the unit operates internally. The importance of implementing proper electrical practices from design to installation is vital to the overall effectiveness and safety of any scenic element that is equipped with electrically-powered components.
We see the certification process as a necessary step in the future success of our industry. Since the early days of scenic fabrication, craftsmen have been turning a designer’s vision into reality. Every year since then, set design has matured with the demanding taste of the audience; scenic elements have grown to be bigger, brighter, and more elaborate. We as an industry are obligated to match this growth with a proactive, vigilant approach to safety. The adage “well that’s how we’ve always done it” is not credible in an industry that is constantly evolving. There has always been, and will always be, an expectation of safety. That expectation should be met with qualified and certified professionals that are involved with every step of the theatrical design, fabrication, and installation process. It is the actions of responsible producers, designers, mechanics, and technicians that have made our industry a successful one. And it will be that same group of people that will advance this industry.
[Editor's Note: Special thanks to Protocol Magazine, official publication of Entertainment Technician Certification Program (ETCP) for contributing this article. ETCP focuses on disciplines that directly affect the health and safety of crews, performers, and audiences. There are two areas of certification - electrical skills and rigging skills, and an entertainment technician may take exams to hold one or more of the following certifications: Rigger–Arena, Rigger–Theatre, and Entertainment Electrician. For more information, please ]
