← Course hubReboot AVStaging & Crew Chief — designed edition
Reboot AV

Staging & Crew Chief

Chapter 01

Introduction

Staging is the first thing in and the last thing out. Everything everybody else does happens on top of it, which means the staging crew works while the floor is empty and again when it is empty, and is blamed by four departments in between for anything that is not level.

The crew chief is the person who decides how the thing gets built, in what order, by whom, and whether it is safe to stand on. It is a promotion out of doing the work and into being responsible for other people doing it, which is a different job with a different set of mistakes.

This book teaches the structures and their limits, the edges and the rules that apply to them, the outdoor standard and its weather plan, and the part that most new chiefs find hardest: running a crew rather than being the fastest person on it.

Chapter 02

What This Book Does Not Do

It does not make you a rigger, and it does not make you an engineer. Flown structures belong to the rigging books, and designing a temporary structure belongs to a qualified engineer.

What it does do is teach you enough to build safely inside a manufacturer's system, to know when a question has stopped being a staging question, and to be the person who says so out loud rather than the person who guesses.

Chapter 03

How to Use This Book

Read it in order. The chapter on loads is the one that underpins every decision, and the chapter on leading the build is the one most worth re-reading after your first call in charge. Every chapter ends with a reference table, a procedure, a failure table written symptom first, an exercise and a checklist.

Keep a notebook

Write down the system you were given and its rated deck load, and keep them together. Legs, decks, clamps and rails are rated as a system, and a note that says which manufacturer's parts were on the truck is what lets you refuse a mixed build without arguing from memory.

Write down the point loads you were asked to put on the stage, not just the total weight. A line array tower, a video wall's ballast or a piano concentrates weight onto a few square inches, and the question the venue needs answered is never "how heavy is it" but "how heavy is it, under this leg, on this floor".

Write down the briefing you gave, in the order you gave it. A crew chief's authority comes from having said the thing before the build, and the notebook is what turns a briefing into something you can repeat identically at the next venue.

A note on the words

A deck is a platform is a riser, and in a theatre it may be a rostrum. Legs are legs, standards, or supports. The rail is a guardrail, a handrail or an edge protection depending on who wrote the drawing. None of it is worth correcting.

What does need pinning down is the system name, because the parts are not interchangeable between them — a Steeldeck, a Bil-Jax, a Prolyte, a Layher and a StageRight all solve the same problem with incompatible hardware. When you are told "stage is on site", ask whose.

A note on safety

A stage is a structure that people walk on and heavy things sit on, built fast by a crew who will not be there when it is used. The hazards are the ones structures have: weight in the wrong place, an unbraced height, an open edge in the dark, and a guardrail that was fitted last instead of first.

Outdoors, add wind. A roof, a banner or a video wall on a stage is a sail, and the wind action plan — who watches, what number triggers what, and who has authority to stop the show — is a document that exists before the build or does not exist at all.

The strike is when people get hurt. The crew is tired, the deadline is real, and the guardrails come off first because they are in the way. Ordering the strike so that each rail stays until the edge it guards has come down is most of a crew chief's contribution to everybody going home.

Where this book sits

This book assumes you have read Set & Stage Etiquette, or that you already know what is in it.

Experience counts instead. If you have several seasons on staging crews, where you have built the same systems enough times to know what a bad build looks like before it finishes, start here.

If none of that is true yet, read Set & Stage Etiquette first.

What pairs with this

  • Physical Preparation for AV — the crew's bodies, which are the chief's problem too

Where it leads

These are not steps in an order. Take whichever one fits.

  • Advanced Rigging — what hangs above the stage you are building
  • Touring Fundamentals — the same build, city after city
Chapter 04

What Staging Is

Start with the work and the role, because the role is not simply "the best person on the crew, promoted".

Building the physical show and leading the crew.

The crew chief

The crew chief is responsible for what gets built and for the people building it. That means deciding the sequence, allocating the crew, checking the work, holding the schedule, and calling a stop when something is not right.

The trap is obvious once said: a chief who is carrying decks is not watching the build. The most useful position is usually standing still, looking at the whole floor, with clean hands and a drawing.

The other half of the job is outward: you are the person the production manager, the venue and the other departments talk to. Whether the stage will be ready at four o'clock is your answer to give, and it needs to be true rather than optimistic.

The promotion took you off the deck A chief who is carrying decks is not watching the build, not answering the production manager, and not seeing the error in row two. HANDS FREE, HEAD UP, RADIO ON WASIS NOWBeing fastest on the deckKeeping the whole floor movingFixing it yourselfShowing somebody once, properlyKnowing your bitKnowing the sequence and the scheduleHead downHead up, with a drawing and a tapeTold the timingsGiving the timings, honestlyThe chief's value is judgement, and judgement shows mostly in what does not happen.
What the promotion changed: five habits that have to go, and what replaces each.

Platforms, risers and what they carry

Staging is the platform everything else stands on: the performance stage, the risers under a drum kit or an orchestra, the thrust, the catwalk, the camera platforms, the FOH riser, the podium and the tiered seating. It is modular, it is heavy, and it is built and taken apart by hand, fast, in the dark, twice a day on a touring show.

What makes it its own trade is that it is structural. A deck is not furniture. It has a rated load, it has to be level and braced, it has edges people can fall off, and there is a void underneath that fills with cable, cases and people.

The systems you meet

Most AV and event staging is one of a handful of systems, and the differences matter because their components do not mix.

  • Steel deck-and-leg systems, such as Steeldeck: a steel frame with a plywood top and separate legs in fixed lengths. Strong, heavy, and the touring default.
  • Aluminium deck systems, such as Litedeck: lighter to handle, different ratings, different legs.
  • Folding-leg staging, such as Sico and similar: fast to set, common in hotels and ballrooms, with fixed heights.
  • Rolling risers: decks on castors, wheeled on and off during a show, usually with their own brakes and locking.
  • Tiered and telescopic seating, and the ramps and stair units that go with any of the above.

Legs, decks, clamps and rails are designed as a system. Mixing a leg from one manufacturer with a deck from another is not a shortcut; it is an unrated structure.

Four staging systems, and their components do not mix Legs, decks, clamps and rails are designed and rated as a system. A leg from one and a deck from another is an unrated structure. ONE SYSTEM PER STRUCTURE STEEL DECK AND LEGload and durabilitytouring stages and risersALUMINIUM DECKlighter to handlecorporate and conferenceFOLDING-LEGfast to set, fixed heightshotels and ballroomsROLLING RISERSmoves during the showbands and set changesStair units and ramps belong to the system too, and are the part most often left off the truck.
Four staging systems, what each is for, and where AV meets it.
What the components actually are.

Where staging goes wrong

The recurring failures are few and specific: a deck loaded past what it will carry, usually by something small and heavy; a stage built out of level or out of square so nothing downstream fits; an open edge nobody guarded during the build; a rail left off because the stair unit was coming later; and a strike done fast by a tired crew in the wrong order.

Each one has an answer in this book, and each one is something a chief prevents by deciding rather than by working harder.

The systems, and what they are for

Components are designed as a system and do not mix between them.

SystemStrengthWhere you meet it
Steel deck and legLoad and durabilityTouring stages, risers, thrusts
Aluminium deckLighter to handleCorporate, conference, fast turnarounds
Folding-leg stagingSpeed to setHotels and ballrooms
Rolling risersMoves during the showBands, orchestras, set changes
Stairs and rampsAccessEvery stage, and often forgotten

What the chief actually does

The job is deciding, not lifting.

DoingInstead of
Deciding the sequenceStarting at whichever end is nearest
Allocating the crewBeing the fastest person on the deck
Checking the work as it goesFinding it at the end
Holding the schedule honestlyHoping it comes right
Calling a stopWorking around a problem

How to do it

  1. Get the drawing and the deck list before the crew arrives.
  2. Walk the floor and find the datum, the obstructions and the access.
  3. Decide the build sequence and the crew split.
  4. Brief the crew, including the hazards and where the edges will be.
  5. Stand where you can see the whole build and check as it goes.
  6. Report honestly on the schedule as soon as you know.

What goes wrong

SymptomLikely causeWhat to do
The chief is carrying decksPromoted for speed, still working at speedStand still and watch; that is the job now
Nothing downstream fitsThe stage is out of square or out of levelBuild from a datum; check early and often
Components from two systems mixedWhatever was in the truckOne system per structure; it is rated as a system
The production is surprised at four o'clockOptimistic reporting earlier in the daySay it early, with what you need to fix it

Practice it

On your next staging call.

Practice it
01
Identify which staging system is in the truck.
Answer
Steel deck-and-leg is the usual touring answer.
02
Find the drawing and the deck count before the crew arrives.
Answer
It is often missing, which is the first problem.
03
Watch the chief and note how much of the time they are lifting.
Answer
New chiefs lift far too much.
04
List every stair unit and ramp on the drawing.
Answer
Access is the most commonly forgotten part of a stage.
Field checklist
  • The drawing and deck list are in hand.
  • The floor has been walked and the datum chosen.
  • The sequence and crew split are decided.
  • The crew has been briefed, including the edges.
  • The chief is positioned to see the whole build.
Chapter 05

Decks, Legs and Loads

Everything a staging crew argues about comes back to one question: what will this deck carry, and where.

Rated load, and what a deck will carry

Staging is rated as a distributed load: so many pounds per square foot, or kilograms per square metre, spread evenly across the deck. Manufacturers publish it per deck size and per leg height, because a taller leg carries less.

Distributed is the important word. A rating that copes with a crowd of people standing evenly across a deck says nothing directly about one very heavy object on a small footprint.

The US scaffold rule (OSHA 29 CFR 1926.451(a)(1)) puts the principle plainly: a scaffold and its components must support their own weight and at least four times the maximum intended load without failure. Staging is not scaffolding, but the principle carries over. That factor is not spare capacity for you to spend. It is there for the things nobody predicted -- a crowd moving in step, a dropped case, a damaged leg.

Point loads, and why a small heavy thing is worse

AV is full of heavy objects with small feet: amplifier racks, battery packs, motors, cable trunks, a grand piano on castors, a drum riser with a stool and a person on it. A three-hundred kilogram rack standing on four castors puts its whole weight through four coin-sized patches of plywood.

The answer is to spread it. Steel plate, plywood sheet, track or proper spreaders under wheels and feet; a deck line chosen so a heavy item sits over a leg rather than in the middle of a span; and a question asked of the manufacturer's data rather than guessed.

If the item is heavy enough that the answer matters, get it in writing from somebody who knows the system, and put it on the drawing so the next crew inherits the decision.

A rating is for weight spread out, not for one heavy thing Staging is rated as a distributed load. An amplifier rack on four castors puts its whole weight through four small patches of plywood. SPREAD IT, AND SIT IT OVER A LEG DISTRIBUTED -- a crowd, evenlythis is what the published rating describesAMP RACKPOINT -- heavy, on four castorsthe rating says nothing about this directlyplate or ply under the wheels, and the item over a leg rather than mid-spanComponents are expected to carry four times the intended load. That margin is for the unforeseen, not for you to spend.
A crowd spread evenly against an amplifier rack on four castors.

Levelling, bracing and what holds it up sideways

A stage has to be level for everything downstream: set pieces, scenic, risers, LED walls and the performers. Screw jacks, shims and adjustable legs do the levelling; the floor decides how much of it you need.

Bracing is the part crews skip because a deck feels solid before it is braced. It is not. Vertical legs carry weight well and resist sideways force poorly, and a stage with a crowd on it gets pushed sideways every time that crowd moves together. Follow the manufacturer's bracing pattern, all of it, including the diagonals that look unnecessary.

Anything at height gets braced sooner rather than later. A partly built stage at leg height with no bracing is the least stable it will ever be, and that is the state crews leave it in when they break for food.

Legs carry weight well and resist sideways force badly A deck feels solid before it is braced. A crowd moving together pushes it sideways, and that is what the diagonals are for. THE BRACING PATTERN IS THE WHOLE PATTERN, DIAGONALS INCLUDED UNBRACEDstiff up and down, loose sidewaysBRACEDthe diagonals take the sideways loadand a part-built stage at leg height with no bracing is the least stable it will ever beWhich is exactly the state crews leave it in when they break for food.
Unbraced against braced -- stiff vertically either way, loose sideways without the diagonals.
Levelling happens at the leg, with a tool.
A braced understructure, from underneath.

Ground bearing and what is underneath

Every leg puts its share of the load into the floor. Indoors that is usually fine, until the stage is over a service void, a basement, a pool cover, a sprung floor or a car park, at which point the venue's limit is the number that matters.

Outdoors the ground carries the load, and grass, mud, sand, gravel and made ground all behave differently and change with the weather. Base plates and spreaders under every leg, and somebody checking the ground during the day rather than only at the start.

The rule is the same as everywhere else in this series: ask what is under it, and ask somebody who actually knows.

The load questions, in order

Answer them before the first deck goes down.

QuestionWhere the answer livesIf unknown
What is the deck rated at?Manufacturer's data for that deck and leg heightDo not load it
Is anything heavy going on it?The production's kit listAsk; assume heavy
Is it a point load?The footprint of the itemSpread it and ask
What is the floor rated at?The venueAsk the venue in writing
What is the ground like outdoors?Site survey and the weatherSpreaders, and check again later

Distributed against point loads

Both matter; only one is on the headline figure.

LoadExampleWhat to do
DistributedA crowd, a choir, a bandCompare with the deck's rating
PointAmp rack on castors, motor, pianoSpread it; sit it over a leg
DynamicPeople jumping in timeAsk an engineer for anything unusual
RollingRolling riser or case crossing the deckTrack or ply; check wheel loads

How to do it

  1. Find the deck's rated distributed load for that leg height.
  2. List what is actually going on it, including people and cases.
  3. Identify anything heavy on a small footprint.
  4. Spread point loads and place them over legs where you can.
  5. Ask the manufacturer or an engineer for anything unusual or dynamic.
  6. Write the decision on the drawing for the next crew.

What goes wrong

SymptomLikely causeWhat to do
A castor through the plywoodA point load on an unspread deckPlate or ply under wheels; sit it over a leg
The stage moves when the crowd movesMissing diagonal bracingThe full bracing pattern, including the diagonals
A leg sinking outdoors during the dayGround softening after rainSpreaders, and re-check during the call
Nobody can say what the deck is rated atMixed systems or missing dataOne system, with its published data to hand

Practice it

With a real stage.

Practice it
01
Find the published rating for the deck system in your truck.
Answer
It is published per deck size and leg height.
02
Work out the heaviest single item going on the stage and its footprint.
Answer
Amp racks and motors are the usual answers.
03
Check the bracing pattern against the manufacturer's drawing.
Answer
Diagonals are the ones most often missing.
04
Ask the venue what the floor under the stage will take.
Answer
Many venues know; some do not, which is also an answer.
Field checklist
  • The deck rating for that leg height is known.
  • Point loads are identified, spread and placed over legs.
  • The full bracing pattern is fitted, including diagonals.
  • Legs sit on spreaders where the ground or floor needs them.
  • Anything unusual has been asked of somebody qualified.
Chapter 06

Staging & Building

Building a stage is an order of operations. Done in the right order it is quick and square; done in the wrong order it is a day of adjustment.

Decks, structure, and building it solidly.

Staging and structure

A stage is a structure with a top surface, and the parts have jobs. Legs carry vertical load. Bracing resists sideways movement. Clamps or couplers hold decks to each other so the surface acts as one. Rails keep people on. Skirting hides the void and keeps things out of it. Stairs and ramps get people on and off.

Nothing on that list is decoration, which is worth saying because rails, bracing and skirting are the three that get left until later and then forgotten.

Building safely and solidly

Build from a datum: one corner or edge that is right, established against the room or the drawing, and everything measured from it. Get the first row square and level and the rest follows; get it wrong and every row after it inherits the error.

Set legs to the right height before decks go on, level as you go rather than at the end, clamp decks together as each one lands, and brace as the height goes up rather than after the deck is complete.

Handle decks with the crew and the technique the job needs: they are heavy, they have pinch points at every corner and clamp, and a dropped deck takes fingers. Gloves, a call before the lift, and nobody walking backwards.

A stage is built in an order, and out of order costs a day Every row after the first inherits whatever the first one got wrong. DATUM FIRST, THEN THE FIRST ROW SQUARE AND LEVEL DATUMone corner, against the drawing1LEGS TO HEIGHTbefore weight goes on them2FIRST ROWsquare, level, checked3OUTWARDclamping as each deck lands4BRACE AS IT GROWSleast stable part-built5RAILS, STAIRS, SKIRTaccess and edges, not last-minute6Checking the first row for square and level takes two minutes and saves an afternoon of shimming.
Six steps from datum to skirting, and what each one is protecting.
Decks are handled by two, with gloves, facing the work.

Guardrails, edges and the height that triggers them

An open edge is the staging hazard. The regulator's general duty is a height trigger -- six feet in construction work, four feet in general industry -- above which an unprotected edge needs a guardrail, a net or personal fall arrest.

Events live awkwardly across those categories, and venues, productions and insurers often set their own lower thresholds. The useful position for a crew chief is simple: know which rule your employer is working to, and treat any edge above about a metre as needing an answer rather than an opinion.

Then there is the part the rules do not cover well. During a build, every edge is open, the height is changing, and the people near it are carrying decks backwards. Guard the edges you can, keep the work moving away from the edge rather than toward it, and put the rails on as the stage grows rather than at the end.

Rails go on the audience-facing edges last on a show stage, because they come off for the performance -- which is exactly why the plan for who fits them, and when they come off and go back on, is agreed at the start of the call rather than at the end.

The finished stage has rules; the build is the dangerous part Height triggers cover a finished edge. During a build the height changes hourly and people carry decks backwards toward it. GUARD WHAT YOU CAN, AND WORK AWAY FROM THE EDGE THE WRITTEN TRIGGERS6 ft -- construction work4 ft -- general industryvenues and insurers often set lower onesWHAT A CHIEF DOESknow which rule your employer works to,and treat any edge above about a metreas needing an answer, not an opinionA GROWING EDGEheight changes hour to hourCARRYING DECKS BACKWARDSnobody sees the edge behind themRAILS OFF FOR THE SHOWthe edge returns at the worst timeagree at the start of the call who fits the rails, and when they come off and go back onNobody walks backwards near an edge, and nobody works under a deck while decks are being handled above.
The written height triggers, what a chief does with them, and the three edge risks during a build.
What a protected edge looks like.

Stairs, ramps and access

Getting people on and off a stage is a design decision, not a detail. Stair units come with handrails and treads designed for them; assembled stairs need to be secured to the stage rather than standing beside it.

Ramps matter more than most crews think: for wheelchair access, for a piano, for rolling risers, and for cases. The gradient decides whether it is usable, and a ramp that is too steep for a wheelchair is also too steep for somebody pushing a heavy case.

Behind the stage, access is just as important and less pretty: steps up from the wings, a route that is lit, and a way out that does not involve stepping off an edge in the dark.

Access is built, secured and railed.

Skirting, masking and what goes under a stage

Skirting hides the legs and finishes the look. It also hides the void, which on a busy show fills with cable, cases, water bottles and occasionally people having a quiet moment.

That matters for three reasons: things under a stage are hard to find in a hurry, a void full of cases is a fire risk, and somebody under a deck is invisible to the crew working on top of it. Keep it tidy, keep it known, and check under the deck before anything heavy goes on top.

Falling objects, and the people below

While a stage is being built, people work under and beside it: running cable, fixing skirting, sorting cases. Anything dropped from the deck lands on them -- a clamp, a drill, a leg, a deck corner.

Toe boards where rails are fitted, tidy decks, tools kept away from the edge, and a rule that the area under an active build is not a storage area. When decks are being handled at height, nobody is underneath.

The build, in order

Out of order is where the day goes.

StepWhy it is hereSkipped means
Establish the datumEverything measures from itThe whole stage inherits an error
Set legs to heightBefore weight goes on themAdjusting under load
First row square and levelIt sets every row afterA day of shimming
Clamp as decks landThe surface acts as oneDecks moving independently
Brace as height growsIt is least stable part-builtA stage that sways
Rails, stairs, skirtingAccess and edgesLeft to the end and forgotten

Edges during a build

The rules cover the finished stage; the build is the dangerous part.

SituationRiskControl
Growing edgeHeight changes hour to hourGuard what you can; work away from it
Carrying decks backwardsNobody sees the edgeNobody walks backwards near an edge
Rails off for the showThe edge returns at the worst timeAgree who refits and when
Work below the deckDropped objectsNobody underneath while decks move

How to do it

  1. Establish and mark the datum against the drawing and the room.
  2. Set the legs for the first row and level them.
  3. Land and clamp the first row, checking square and level.
  4. Work outward, bracing as the structure grows.
  5. Fit rails, stairs and access as the stage reaches its height.
  6. Skirt last, after checking under the deck is clear and known.

What goes wrong

SymptomLikely causeWhat to do
The stage is out of square by the far cornerNo datum, or the first row not checkedDatum first, first row square and level
A crushed finger at a clampRushed deck handling and no glovesCall the lift, gloves, nobody walking backwards
Rails still off at doorsLeft to the end of the callFit as the stage grows; agree who owns the rails
Something dropped onto the cable crewPeople working under an active buildNobody underneath while decks are handled

Practice it

On your next build.

Practice it
01
Find the datum used and check it against the drawing.
Answer
Many crews never establish one explicitly.
02
Check the first row for square and level before the second goes on.
Answer
It takes two minutes and saves hours.
03
Note when bracing was fitted relative to the height.
Answer
Bracing is usually late.
04
Look under the deck an hour before doors.
Answer
The void is usually full of things nobody remembers putting there.
Field checklist
  • A datum was established and the first row checked square and level.
  • Decks are clamped and the bracing pattern is complete.
  • Edges are guarded or the work is moving away from them.
  • Stairs, ramps and rails are fitted, secured and agreed.
  • The void under the deck is tidy, known and checked.
Chapter 07

Leading the Build

The part of the job that is not about staging at all. A crew chief who understands decks and not people will have a level stage and a crew that does not want to come back.

Run the crew and the build as a crew chief.

Leading the crew

You are leading people who are often freelance, frequently new to you, sometimes new to staging, and always tired by the end. What they need from you is clarity: what is being built, in what order, who is doing what, where the hazards are, and when the breaks are.

Most of what people call a bad crew is a briefing failure. Crew who do not know the sequence make sensible guesses that do not fit each other. Crew who do not know the finish time pace themselves wrongly. Crew who do not know which edge is live walk backwards toward it.

The other half is respect, which on a load-in is expressed practically: learning names, giving the unpleasant job to different people rather than the same one, saying when something was done well, and being the person who takes the blame outward and the credit inward.

Running the build

The crew chief runs the build — managing the whole build operation: organizing the work and sequence, setting the pace (efficient but safe), solving problems, ensuring quality and safety, and getting the build done correctly and on time. The crew chief owns the build — its quality, safety, and schedule. Running the build well (efficient, safe, on-time, correct) is the crew chief's core responsibility.

This means the crew chief manages the build as a whole — the crew, the work, the pace, the quality, the safety, the schedule — delivering a well-built stage/set on time. A good crew chief runs a smooth, safe, efficient build; a poor one runs a chaotic or unsafe one.

Briefing a crew

A good staging briefing takes three minutes and contains the same things every time.

  • What we are building, and where it goes on the floor.
  • The sequence, and which part each group starts on.
  • Who is leading each group, and who to ask.
  • The hazards: edges, heights, pinch points, machines, other departments.
  • Where the gear is, and where the empties go.
  • Timings: breaks, and what has to be done by when.
  • The stop rule -- anybody can call a stop, and nobody gets grief for it.

Then take questions, because the question somebody asks in the briefing is the mistake they were about to make.

Seven things, three minutes, every call Most of what gets called a bad crew is a briefing failure: people making sensible guesses that do not fit each other. EVERY QUESTION ASKED IS A MISTAKE AVOIDED WHAT AND WHEREpeople build what they pictureSEQUENCE AND GROUPSstops guesses that do not fitWHO LEADS WHATsomebody to ask that is not youHAZARDSedges, heights, pinch points, machinesGEAR AND EMPTIEShalf the wasted time on a callTIMINGS AND BREAKSpeople pace to the finish they knowTHE STOP RULEanybody can stop; nobody gets griefThen take questions. A briefing that ends without one has usually not been understood.
The seven things a staging briefing contains, and why each one is there.
The call starts with everybody listening.

Delegation, and doing less of the work yourself

The commonest mistake a new chief makes is working. It feels productive, it is what you were good at, and it is why you were promoted. It also means nobody is watching the build, nobody is answering the production manager, and nobody notices that the second row is a centimetre out.

Delegate in groups with a name on each: this pair sets legs, this group lands decks, this one braces behind them, this one does rails and stairs. Give each group its own finishing point so progress is visible.

Then stand where you can see it, check as it goes rather than at the end, and keep your hands free for a tape measure, a drawing and a radio.

Hands free, head up.

Correcting work without losing the crew

Some of what gets built will be wrong, and the chief has to say so. How it is said decides whether the crew tells you about the next problem or hides it.

What works is specific, quick and about the work: what is wrong, why it matters, what to do instead, and then move on. What does not work is doing it silently yourself, saving it up for later, or saying it in front of the whole crew when it could be said to one person.

And when the mistake came from your own briefing -- which it often did -- say that too. A chief who takes that on gets told about problems early for the rest of the tour.

Pace, breaks and a long call

Staging is heavy work in bursts. People go fast at the start, slow in the middle and get careless at the end, and the injuries cluster in that last part.

Set a pace the crew can hold, take the breaks rather than promising them, rotate the heaviest jobs, and notice who is struggling before they say anything. Water and food are not a courtesy on a twelve hour call; they are part of the crew working safely at hour eleven.

If the schedule cannot be met at a safe pace, that is information for the production manager rather than something to be absorbed by a crew going faster.

Working with the other departments

Staging is first in and everybody is waiting. Audio needs the deck for the band gear, lighting needs the floor for the truss, video wants the wall position, and all three want it now.

Agree the sequence with the production manager and then hold it, tell the other heads when their area will be free, and give them a real answer rather than a comfortable one. Where two departments genuinely need the same space, it is a scheduling decision for the production manager, not an argument between two crews.

And at the end of the build, walk the stage with the other departments so what they inherit is what they expect.

The crew chief leads the build crew — directing and organizing the crew building the stage/set, assigning the work, leading the team, and getting the build done — hands-on crew leadership (applying crew-leadership skills to the physical build), coordinating the work and keeping the team productive and safe as the leader the crew follows. The crew chief also runs the build — managing the whole operation: organizing the work and sequence, setting the pace (efficient but safe), solving problems, ensuring quality and safety, and getting it done correctly and on time — owning the build's quality, safety, and schedule, delivering a well-built stage/set on time (a good crew chief runs a smooth, safe, efficient build).

The briefing, every time

Three minutes, and the same seven things.

ItemWhy it matters
What and wherePeople build what they picture
Sequence and groupsStops sensible guesses that do not fit
Who leads whatSomebody to ask that is not always you
HazardsEdges, heights, pinch points, machines
Gear and emptiesHalf the wasted time on a call
Timings and breaksPeople pace to the finish they know about
The stop ruleAnybody can stop; nobody gets grief

Doing against leading

What the promotion actually changed.

WasIs now
Being fastest on the deckKeeping the whole floor moving
Fixing it yourselfShowing somebody, once, properly
Knowing your bitKnowing the sequence and the schedule
Head downHead up, hands free
Told the timingsGiving the timings, honestly

How to do it

  1. Brief the whole crew before anybody touches anything.
  2. Split into named groups with their own finishing points.
  3. Stand where the whole build is visible and check as it goes.
  4. Correct quickly, specifically, and to the person rather than the room.
  5. Take the breaks and rotate the heavy jobs.
  6. Report progress to the production manager before you are asked.
  7. Walk the finished stage with the other departments.

What goes wrong

SymptomLikely causeWhat to do
Two groups build to different plansNo briefing, or no sequence in itBrief the sequence and the groups every call
The chief is invisible and unreachableWorking on the deck instead of leadingHands free, head up, radio on
The crew stops telling you about problemsCorrections made publicly or unfairlyQuick, specific, private, and own your own briefing errors
Injuries in the last hourA pace the crew could not hold, breaks skippedSet a holdable pace; take breaks; escalate the schedule

Practice it

On your next call, whether or not you are in charge.

Practice it
01
Write the seven-item briefing for that build.
Answer
Hazards and empties are the items usually missing.
02
Time how long the briefing actually took.
Answer
Three minutes is enough; most briefings are under one.
03
Watch how much of the call the chief spends lifting.
Answer
Too much, in almost every case.
04
Notice when the crew's pace drops and what happened next.
Answer
Usually about hour eight, and the mistakes follow.
Field checklist
  • Everybody was briefed and knows the sequence and hazards.
  • Work is split into named groups with visible finishing points.
  • The chief has hands free and can see the whole floor.
  • Corrections are quick, specific and private.
  • Breaks are taken and the heavy jobs rotate.
  • The production manager hears the truth early.
Chapter 08

Outdoor Staging and Weather

Outdoors, the structure gets a standard, an engineer and a weather plan, and the crew chief acquires a set of decisions that are not about building at all.

What changes outdoors

Outdoors the ground moves, the weather has a vote, and the structure is usually more than a platform: a roof, wings, delay towers, screen supports, barricade and a mix-position tower.

Those overhead and ground-supported structures are the subject of a published standard, ANSI/ESTA E1.21, which covers temporary ground-supported structures used in the technical production of outdoor entertainment events -- their design, manufacture, use and maintenance. It specifically excludes pre-engineered modular staging used as a performance platform on its own, which is why the deck you are building may sit outside it while the roof above you does not.

What that means for a crew chief is straightforward: outdoor structures come with an engineer, drawings, a permitted configuration and a person made responsible for it. Your job is to build to the drawing, to say when reality does not match it, and never to improvise a structural change.

The outdoor stage is a structure, not a platform.

The competent person and the paperwork

Outdoor structures are built and operated under somebody named: the engineer who designed it, and the competent person on site responsible for its use, its inspection and the decision to stop. On a festival that person may be the production's structural contractor rather than anybody on your crew.

Find out who it is on the first morning. If the answer is vague, that is the most important thing you will learn all week, and it is a question for the production manager rather than a problem to solve yourself.

The wind action plan

Every outdoor structure works to wind speeds, and the document that turns those into decisions is the wind action plan. It states what happens at each threshold: monitor, stop lifting, drop banners and scrim, clear the structure, clear the audience.

For it to work, three things have to be true. Somebody is actually measuring wind at the right place, continuously, rather than guessing. The thresholds are known to the people who must act on them. And the authority to call a stop is named and available, which means somebody who is awake, on site and reachable.

Scrim, banners and any large flat surface are the part that surprises people: they turn a structure into a sail, and the plan usually requires them off long before the structure itself is at risk.

A wind action plan works only if four things are true Somebody measuring, thresholds people know, a named person with the authority to stop, and the sails off early. OTHERWISE IT IS A DOCUMENT, NOT A PLAN MEASUREDcontinuously, in the right placenot somebody guessing on the groundKNOWNthresholds briefed to the crewnot a plan nobody has readNAMEDauthority to stop, awake and reachablenot waiting for a call backSAILS OFF EARLYscrim and banners come down firstnot a structure turned into a sailOutdoor structures come with an engineer and a named competent person. Find out who they are on the first morning.
Measured, known, named and sails off early -- or it is a document rather than a plan.

Ballast, anchoring and staying put

An outdoor structure has to be held down as well as held up. That means ballast -- water, concrete, weights -- or ground anchors, stakes and guys, to the engineer's specification and not to the crew's judgement.

Two practical traps recur. Ballast that is specified but only partly delivered, so the structure stands with half its hold-down in the car park. And ground anchors into ground nobody has surveyed, which on a made-up site can mean services underneath.

Count the ballast, check it against the drawing, and say something if the numbers do not match.

Weather through the day

Rain changes the ground under the legs, makes decks slippery and makes electrical decisions for other departments. Heat changes the crew. Lightning is its own plan, with its own distances and waiting times, and it is not a judgement call made by a crew chief looking at the sky.

The workable habit is to keep looking: at the forecast, at the anemometer, at the ground under the legs, and at the crew. And to raise what you see early, because outdoor decisions get much more expensive the later they are made.

Who is responsible for what, outdoors

Establish these names on the first morning.

RoleOwnsAsk them about
EngineerThe design and the permitted configurationAny change to the structure
Competent person on siteIts use, inspection and stopping itWind thresholds and who calls it
Production managerThe schedule and the decisionsAnything the drawing does not match
Crew chiefBuilding it to the drawingSaying when reality differs

The wind action plan works when

All four, or it is a document rather than a plan.

RequirementFailure mode
Wind is measured continuously and in the right placeSomebody guessing on the ground
Thresholds are known to the crewA plan nobody has read
Authority to stop is named and reachableWaiting for a call back
Scrim and banners come off earlyA structure turned into a sail

How to do it

  1. Find out who the engineer and the on-site competent person are.
  2. Get the drawing and the permitted configuration, and build to it.
  3. Count the ballast or check the anchoring against the specification.
  4. Read the wind action plan and confirm who measures and who calls a stop.
  5. Check the ground under the legs through the day, especially after rain.
  6. Raise any difference between the drawing and reality immediately.

What goes wrong

SymptomLikely causeWhat to do
Nobody can name the competent personResponsibility assumed rather than assignedAsk on the first morning; escalate if vague
Half the ballast is still on a truckDelivery short, and nobody countedCount it against the drawing before it is needed
Banners still up in rising windThe plan not read by the people who act on itThresholds briefed to the crew, not just filed
A structural change improvised on siteThe drawing did not fit realityStop; the engineer decides, not the crew

Practice it

On your next outdoor job.

Practice it
01
Name the engineer and the on-site competent person.
Answer
If nobody can, that is the finding to escalate.
02
Read the wind action plan and write down its thresholds.
Answer
Most crews have never seen it.
03
Find out who is measuring wind, and where the anemometer is.
Answer
Often nobody, or a phone app.
04
Count the ballast against the drawing.
Answer
Short deliveries are common.
Field checklist
  • The engineer and the competent person are named and reachable.
  • The build matches the drawing and no change has been improvised.
  • Ballast or anchoring matches the specification and has been counted.
  • The wind action plan is read, briefed, and somebody is measuring.
  • Ground and weather are re-checked through the day.
Chapter 09

Safety, Schedule & Strike

The three things a crew chief is judged on, and the one most likely to hurt somebody.

Build safe and on time, then take it down.

Safety and schedule

Staging has its own injuries and they are not exotic: crushed fingers at clamps and corners, backs from lifting decks badly, feet from dropped legs, falls from open edges, and cuts from deck edges and hardware.

Every one of them gets more likely when the call is behind, which is why safety and schedule are the same subject for a crew chief. A crew that is being asked to catch up is a crew about to get hurt.

What a chief actually controls is the pace, the sequence and the information. If the build cannot be finished safely in the time available, the honest move is to say so early with what you need: more crew, a later doors, or a reduced scope. Absorbing it silently is a decision to risk people, made quietly.

The strike

Strike is the fastest and most dangerous part of staging. The crew is tired, the lighting is going away around them, everything is coming apart at once and there is a truck outside with a driver's hours running down.

It is also the part with the least planning attached, which is backwards. A strike needs a briefing exactly like a build: the order, the groups, where the empties are, what goes in first, and where the hazards are now that the floor has changed.

Strike in reverse order: skirting off first; the stage broken down from the edges inward, each rail and stair unit coming off only with the deck it serves, so no edge is left open at height; bracing comes off last from anything at height, not first. A part-struck stage with its rails or bracing pulled is as dangerous as a part-built one, and it usually has more people standing on it.

Then pack the way the truck needs it, not the way the floor produces it, and keep a count. The cases that do not make the truck become somebody's problem in another city.

Strike is the build in reverse, with bracing off last The fastest and most dangerous part of the job, and the part with the least planning attached. BRIEF THE STRIKE THE WAY YOU BRIEF THE BUILD BRIEF ITthe floor and hazards have changed1SKIRTING OFFrails and stairs stay on2EDGES INWARDeach rail leaves with its deck3BRACING LASTpart-struck is as unstable as part-built4PACK TO THE TRUCKnot the order the floor produces5COUNT AND RECORDthe next city inherits the count6A tired crew at maximum speed on a changed floor is where staging's injuries actually happen.
Six steps of a strike, in the reverse of the build, with bracing last.

Reading the schedule honestly

The production manager needs an answer they can plan against, not an optimistic one. Three sentences do the job: what is done, what is left, and when it will be finished at the current pace.

Say it when you know rather than when it is obvious. The cost of telling somebody at eleven that the stage will be late at four is a conversation; the cost of telling them at half past three is a show.

The handover and the paperwork

What gets written down is what the next crew inherits: the deck count, the damaged items, the decisions made on site, anything unusual about the floor or the ground, and anything that was agreed with another department.

Incidents and near misses get written down too, including the ones where nobody was hurt. A near miss recorded on this show is what stops the same thing happening on the next one.

And a walk of the empty floor before you leave: nothing left under where the stage was, nothing in the void, no hardware in the corners, and the venue's floor as you found it.

The floor is walked and left as it was found.

Staging's own injuries

Specific, repetitive, and worse when the call is behind.

InjuryWhere it happensWhat prevents it
Crushed fingersClamps, corners, folding legsGloves, calling the lift, no rushing
BacksLifting decks alone or badlyTeam lifts, technique, rotation
Dropped legs on feetHanding legs downBoots, pass rather than drop
FallsOpen edges during build and strikeGuard edges; work away from them
CutsDeck edges, hardware, damaged plyGloves; pull damaged decks from service

Strike, in order

The reverse of the build, with bracing last.

StepWhy
Brief the strikeThe floor and the hazards have changed
Skirting off; rails and stairs stayEdges stay guarded and access stays open
Break down from the edges inwardA stable core; each rail leaves with its deck
Bracing off last at heightPart-struck is as unstable as part-built
Pack to the truck's orderNot the order the floor produces
Count and recordThe next city inherits the count

How to do it

  1. Brief the strike: order, groups, empties, hazards as the floor now is.
  2. Take off the skirting; leave rails and stairs on while the deck is at height and people need access.
  3. Break the stage down from the edges toward the middle, taking each rail and stair unit off only with the deck it serves.
  4. Leave bracing in place until the height has come down.
  5. Pack in the truck's order and keep a running count.
  6. Walk the empty floor, then write the handover.

What goes wrong

SymptomLikely causeWhat to do
An injury in the last hour of strikeTired crew, no briefing, maximum speedBrief the strike; hold a pace; rotate
A part-struck stage sways with people on itBracing pulled earlyBracing comes off last at height
Cases missing in the next cityNo count at the truckCount as it loads, and record it
The venue complains after you have goneNobody walked the floorWalk it; leave it as you found it

Practice it

On your next strike.

Practice it
01
Note whether there was a briefing before it started.
Answer
Strike briefings are rare and should not be.
02
Watch when the bracing came off relative to the height.
Answer
Too early, usually.
03
Count the decks as they load and compare with the deck list.
Answer
The count rarely matches the first time.
04
Walk the empty floor and list what was left behind.
Answer
There is always something in the void.
Field checklist
  • The strike was briefed like a build.
  • The stage came down from the edges, rails leaving with their decks and bracing off last.
  • The pack matches the truck's order and the count is recorded.
  • Damage, incidents and near misses are written down.
  • The floor was walked and left as it was found.
Chapter 10

Staging & Crew Chief Mastered

What to keep, and how to keep getting better at a job that is mostly judgement.

Building the show and leading the build.

Developing as a staging crew chief

Get the systems under your hands -- build with more than one deck system, and read their published data rather than learning them by feel. Learn to read a stage drawing properly, including the sections and the details nobody looks at.

Work with chiefs who are better than you and watch where they stand, what they check, and what they say to the production manager. Ask to run small calls before large ones. And take the related training seriously: manual handling, working at height, first aid, and the lift tickets, because a chief who can operate the machine has more ways to solve a problem.

For outdoor work, learn the structures side properly: who the engineer is, what E1.21 covers, what a wind action plan contains, and what a competent person is responsible for.

Practical sign-off

Staging is learned building real shows. The learner builds staging safely and solidly, leads a build crew, runs the build on time, and leads the strike, always safely. A mentor signs off when the learner can build and lead a staging build.

  • Built staging safely and solidly (decks, structure, set)
  • Led a build crew as a crew chief
  • Ran the build efficiently, safely, and on time
  • Led the strike safely and efficiently

What the job comes down to

Hold on to a few things. Staging is structural: rated loads, distributed against point, bracing that is not optional, and a floor or a ground that has its own limit. Build from a datum, get the first row right, brace as you grow, and fit the edges as the stage reaches its height rather than at the end.

Outdoors there is a standard, an engineer and a competent person, and a wind action plan that only works when somebody is measuring and somebody is named to call a stop.

And the crew is half the job. Brief properly, split into named groups, keep your hands free, correct quickly and privately, take the breaks, and tell the production manager the truth early.

Underneath all of it: the chief's value is judgement, and judgement is visible mostly in what does not happen.

Four things the chief owns, and how each one fails All four are decisions rather than tasks, which is what makes the job different from being good on the deck. THE STRUCTURE · THE CREW · THE SCHEDULE · THE HANDOVER THE STRUCTURErated, level, braced, edgeda stage that sways or sinksTHE CREWbriefed, split, paced, respectedguesswork and late injuriesTHE SCHEDULEan honest answer, earlya surprise at half past threeTHE HANDOVERcounts, damage and decisions writtenthe next city inheriting a mysterySay the schedule when you know it, not when it is obvious: at eleven it is a conversation, at half past three it is a show.
The structure, the crew, the schedule and the handover -- and how each one fails.

What to do on Monday

  • Find the published load rating for the deck system you use most.
  • Write the seven-item briefing for your next call and use it.
  • Ask who the competent person is on your next outdoor job.
  • Time how long you spend lifting on your next call, and halve it.
  • Brief the strike the way you brief the build.

Each is small, and each moves you from being the fastest person on the crew to being the person the crew works for.

What the chief owns

Four things, and all of them are decisions.

OwnsLooks likeFails as
The structureRated, level, braced, edgedA stage that sways or sinks
The crewBriefed, split, paced, respectedGuesswork and injuries late in the call
The scheduleAn honest answer, earlyA surprise at half past three
The handoverCounts, damage, decisions written downThe next city inheriting a mystery

How to do it

  1. Build with more than one deck system and read their published data.
  2. Learn to read stage drawings including sections and details.
  3. Watch better chiefs and note where they stand and what they check.
  4. Ask to run small calls before big ones.
  5. Take manual handling, height, first aid and lift training.
  6. Learn the outdoor structures side and who is responsible for what.

What goes wrong

SymptomLikely causeWhat to do
A chief who is still the fastest builderDoing the old job in the new roleHands free, head up, checking as it goes
Decisions nobody can explain laterNothing written downRecord decisions on the drawing and in the handover
The same problem every venueNothing learned between callsA short debrief with the crew after big builds

Practice it

This week.

Practice it
01
Read the published data for your usual deck system.
Answer
Most people have never read it.
02
Run your next briefing to the seven items.
Answer
It takes three minutes and changes the call.
03
Ask one better chief what they check first on a build.
Answer
Usually square, level and the first row.
04
Debrief your crew for five minutes after the next big call.
Answer
Five minutes finds things a month of calls would not.
Field checklist
  • You can explain rated load, point loads and why bracing is not optional.
  • You can describe the build order from datum to skirting.
  • You know the height triggers and how edges are handled during a build.
  • You can run a seven-item briefing without notes.
  • You know what a wind action plan must contain and who calls the stop.
  • You know the strike is briefed like a build, with bracing off last.
Chapter 11

Glossary

BallastWeight -- water, concrete or blocks -- used to hold an outdoor structure down.
BracingThe diagonals and horizontals that stop a structure moving sideways.
Competent personThe named person responsible on site for a temporary structure's use, inspection and stopping it.
DatumThe corner or edge everything else is measured and squared from.
DeckA single staging platform, usually a frame with a plywood top.
Distributed loadWeight spread evenly across a deck; the way ratings are published.
E1.21The ANSI/ESTA standard for temporary ground-supported structures at outdoor entertainment events.
Folding-leg stagingStaging whose legs fold under the deck; fast to set, fixed heights.
GuardrailThe rail protecting an open edge, with its mid-rail and toe board.
LegThe vertical member carrying a deck's load, in fixed or adjustable lengths.
LitedeckA widely used aluminium deck system.
Point loadA heavy item on a small footprint, which a distributed rating does not cover.
Rated loadThe load a deck may carry at a given leg height, published by its maker.
Rolling riserA deck on castors, moved on and off during a show.
Screw jackAn adjustable foot used to level a leg.
SkirtingFabric or panel hiding the void beneath a stage.
SpreaderPlate, ply or timber spreading a load into the floor or the ground.
Stair unitA prefabricated set of steps with handrails, secured to the stage.
SteeldeckA widely used steel deck-and-leg staging system.
StrikeTaking the stage apart and packing it.
ThrustA stage extension reaching into the audience.
Toe boardThe upstand at deck level that stops objects being kicked off an edge.
Wind action planThe document giving wind thresholds and the actions taken at each.
Visual glossary

What the gear actually looks like

Every device named in this book, in one place. Recognition is the whole point of Chapter 4 — use this page to attach a picture to each name before you meet it on a dock at six in the morning.

Audio
Dynamic microphone
Dynamic microphone
Condenser microphone
Condenser microphone
Wireless handheld
Wireless handheld
Radio rack
Radio rack
Mixing console
Mixing console
Stage box / snake
Stage box / snake
Power amplifier
Power amplifier
Main loudspeaker
Main loudspeaker
Subwoofer
Subwoofer
Stage monitor wedge
Stage monitor wedge
In-ear monitors
In-ear monitors
DI box
DI box
Video
Camera
Camera
Video switcher
Video switcher
Scaler / processor
Scaler / processor
Projector
Projector
LED wall panel
LED wall panel
Confidence monitor
Confidence monitor
Lighting & control
Conventional fixture
Conventional fixture
Moving-head fixture
Moving-head fixture
Lighting console
Lighting console
Dimmer
Dimmer
Show controller
Show controller
Media server
Media server
Networking & infrastructure
Network switch
Network switch
Patch bay
Patch bay
Equipment rack
Equipment rack
Power distribution
Power distribution
Cable tester
Cable tester
A properly coiled cable
A properly coiled cable
Connectors, close up
XLR
XLR
TRS / TS ¼-inch
TRS / TS ¼-inch
SDI on BNC
SDI on BNC
HDMI
HDMI
Cat5e / Cat6 (RJ45)
Cat5e / Cat6 (RJ45)
Fiber optic
Fiber optic
DMX (5-pin XLR)
DMX (5-pin XLR)
AC power — not signal
AC power — not signal
Reboot AV
Find the source.
Find the destination.
Work along the path between them.
Every device on every show exists to serve that movement. Everything after Staging & Crew Chief goes deeper in one direction.
rebootav.tech