Truss Systems

This SOP defines the standards and procedures for the preparation, assembly, installation, use, and strike of truss systems used by Maryland Productions (MP) and Event Revolution (RV). Truss is a primary structural element in many productions and must be handled with precision, planning, and strict safety compliance.

Improper truss handling or assembly can result in catastrophic failure.

Purpose

  • Ensure all truss systems are assembled and used safely.

  • Prevent structural failures caused by incorrect assembly or loading.

  • Standardize truss prep, inspection, and installation workflows.

  • Define clear responsibilities for truss-related work.

  • Support safe collaboration between rigging, lighting, video, and power teams.

Who This SOP Is For

  • Rigging technicians

  • Lead riggers

  • Technical Directors

  • Project Managers overseeing truss-based systems

  • Warehouse staff prepping truss

  • Freelancers authorized to work with truss

Only trained personnel may assemble or install truss systems.

Scope

This SOP applies to:

  • Box truss

  • Triangle truss

  • Pipe truss

  • Truss corners, circles, and specialty sections

  • Truss connection hardware (bolts, spigots, pins)

  • Ground-supported and flown truss systems

This SOP does not replace engineered drawings or venue-specific structural requirements.

Truss Safety Fundamentals

  • Never exceed manufacturer load ratings.

  • All truss systems must be properly supported.

  • Load calculations must include: - Truss self-weight - Fixtures and equipment - Cable weight - Dynamic loads

  • Use only compatible truss and hardware.

  • Stop work authority applies at all times.

Truss failures can be fatal.

Training & Authorization

  • Only trained personnel may assemble truss.

  • Complex structures require lead rigger oversight.

  • Freelancers must demonstrate familiarity with the truss type in use.

  • PMs must ensure qualified crew for the truss scope.

Unqualified assembly is prohibited.

Warehouse Prep

  • Inspect truss sections for: - Cracks - Bent chords - Damaged welds

  • Inspect connection hardware: - Correct type - No deformation - Proper fit

  • Verify truss compatibility.

  • Pack truss by type and length.

  • Include correct hardware for each system.

Damaged truss must be removed from service.

Planning & Load Calculations

  • Review truss layout and drawings.

  • Calculate loads per span and pick point.

  • Confirm support method: - Motors - Towers - Bases

  • Coordinate fixture placement with lighting and video teams.

  • Verify venue capacity.

Never assume load capacity.

On-Site Assembly

Ground Assembly

  • Assemble truss on flat, stable ground.

  • Align chords and diagonals properly.

  • Insert all connection hardware fully.

  • Secure all pins, bolts, or spigots.

  • Double-check every connection.

Incomplete connections are unacceptable.

Flown Truss

  • Verify motor spacing and capacity.

  • Attach motors using approved hardware.

  • Lift truss slowly and evenly.

  • Monitor for twisting or binding.

  • Stop immediately if abnormal behavior occurs.

Flown systems require constant vigilance.

Ground-Supported Truss

  • Use rated bases and towers.

  • Verify base footprint and ballast requirements.

  • Level structures before loading.

  • Secure towers as required.

Ground support must be engineered appropriately.

Load Attachment

  • Attach equipment using approved hardware.

  • Distribute loads evenly.

  • Avoid point-loading when possible.

  • Secure all fixtures with secondary safeties.

Load placement affects structural integrity.

Inspection & Redundancy

  • Inspect truss after assembly and before loading.

  • Verify all connections are secure.

  • Confirm safeties and redundancies.

  • Re-inspect after major changes.

Inspection is continuous, not one-time.

Strike & De-Rigging

  • Remove loads before disassembly.

  • Lower flown truss fully before disconnecting.

  • Remove hardware carefully.

  • Inspect truss during strike.

  • Separate damaged components immediately.

Strike must be controlled and methodical.

Handling & Storage

  • Do not drop or drag truss.

  • Protect truss from impact.

  • Store truss on proper racks.

  • Keep truss clean and dry.

  • Keep hardware organized and labeled.

Proper handling extends truss lifespan.

Roles & Responsibilities

Rigging Technicians

  • Assemble and install truss safely.

  • Follow approved plans.

  • Report issues immediately.

Lead Riggers

  • Oversee truss operations.

  • Verify calculations and assembly.

  • Enforce safety standards.

Project Managers

  • Define truss scope.

  • Verify crew qualifications.

  • Coordinate venue approvals.

Warehouse Staff

  • Inspect and prep truss.

  • Maintain organized storage.

  • Remove unsafe truss from service.

Quality Control

  • No damaged truss in use.

  • All connections verified.

  • Loads within limits.

  • Safety issues corrected immediately.

Truss safety is non-negotiable.