Rigging Truss

This SOP defines the standards and procedures for inspecting, handling, assembling, deploying, and striking truss systems used by Maryland Productions (MP) and Event Revolution (RV). Truss is a primary structural component in entertainment rigging and must be treated as load-bearing, safety-critical equipment.

Improper truss use can result in structural failure, injury, or catastrophic equipment loss.

Purpose

  • Ensure safe and correct use of truss systems.

  • Standardize truss inspection, assembly, and deployment.

  • Prevent failures caused by damaged components or improper connections.

  • Protect personnel, performers, venues, and equipment.

  • Establish clear expectations for truss handling and load limits.

Who This SOP Is For

  • Rigging technicians

  • Lead riggers and Technical Directors

  • Warehouse staff prepping truss

  • Project Managers overseeing rigging scope

  • Authorized freelancers assembling or working on truss

Only trained and authorized personnel may assemble or modify truss systems.

Scope

This SOP applies to:

  • Box truss

  • Triangle truss

  • Spigoted and bolted truss systems

  • Truss corners, tees, and specialty sections

  • Truss baseplates and top plates

  • Truss used for ground-supported or flown systems

Lighting clamps and motors are covered in separate SOPs.

Truss Safety Rules

  • Never exceed manufacturer load ratings.

  • Never mix incompatible truss systems.

  • Inspect every piece before use.

  • Never modify truss components.

  • Do not load truss until fully assembled and secured.

  • Stop immediately if truss behavior seems abnormal.

Structural integrity is non-negotiable.

Truss Identification & Compatibility

  • Verify: - Manufacturer and model - Truss type and size - Connection system (spigot, bolt, etc.)

  • Never mix: - Different manufacturers - Different series - Different connection types

If compatibility is uncertain, do not assemble.

Warehouse Prep & Inspection

Before deployment:

  • Inspect truss chords for: - Cracks - Dents - Bends

  • Inspect welds for: - Cracking - Separation

  • Inspect connection points for: - Deformation - Excessive wear

  • Verify all required hardware is present.

  • Remove damaged truss from service immediately.

Truss must be inspected before every use.

Truss Assembly

Assembly Standards

  • Assemble truss on level ground.

  • Use proper pins, bolts, and safety clips.

  • Fully seat all connections.

  • Engage all safety devices.

  • Confirm alignment before loading.

Incomplete connections are unsafe.

Orientation & Alignment

  • Verify correct orientation of chords and diagonals.

  • Align truss straight before lifting.

  • Avoid twisting or racking during assembly.

Misalignment weakens truss.

Ground-Supported Truss

  • Use rated baseplates or towers.

  • Verify ground conditions and level surfaces.

  • Install ballast or outriggers as required.

  • Confirm vertical alignment.

  • Apply secondary stabilization where required.

Ground support requires careful planning.

Flown Truss

  • Verify pick points and spacing.

  • Use rated hardware only.

  • Coordinate lifts with motor operators.

  • Keep personnel clear during movement.

  • Inspect after final trim.

Flown truss requires heightened safety.

Load Considerations

  • Account for: - Static loads - Dynamic loads - Wind (outdoor shows)

  • Distribute loads evenly.

  • Avoid point loads unless engineered.

  • Confirm total load is within ratings.

Load planning is mandatory.

Operational Monitoring

During operation:

  • Monitor for: - Movement - Sagging - Unusual noises

  • Re-check critical connections if conditions change.

  • Stop work if instability is observed.

Conditions can change over time.

Strike & Reset

  • Remove loads before disassembly.

  • Lower flown truss in a controlled manner.

  • Disassemble carefully.

  • Inspect components during strike.

  • Flag damaged pieces immediately.

  • Scan truss back into inventory.

Strike is a key inspection opportunity.

Handling & Storage

  • Handle truss with team lifts when required.

  • Protect connection points during transport.

  • Store truss on proper racks.

  • Keep different truss types segregated.

  • Maintain organized storage areas.

Proper storage preserves structural integrity.

Roles & Responsibilities

Rigging Technicians

  • Assemble and handle truss safely.

  • Follow approved rigging plans.

  • Report damage or concerns immediately.

Lead Riggers / Technical Directors

  • Approve truss configurations.

  • Verify load calculations.

  • Enforce safety standards.

Warehouse Staff

  • Inspect, prep, and reset truss.

  • Remove damaged truss from service.

Project Managers

  • Ensure proper rigging scope and staffing.

  • Support safety-driven decisions.

Quality Control

  • Truss inspected before every use.

  • Compatible systems only.

  • Loads within rated limits.

  • Issues documented and addressed.

Truss safety protects everyone below.