Accidents Happen, Stagehand Safety

This Stagehand Safety article was inspired by a recent close call.

It’s a good reminder for all production professionals regardless of position or experience level.

Judging by the engagement level of most veteran crew members, it seems we take Stagehand Safety for granted that accidents can still happen, even when are disciplined and exercise safe practices. Since we are careful, and attentive about actions and behaviors, we start to believe we will stay out of harm's way, or maybe at least be prepared in the event of an incident.

I know I’m guilty of it from time to time. Since I always get in and out of a lift properly, I always call my movements clearly and watch for bystanders, I am careful with tools and instruments I’m working with and I wear a harness and hard hat when required, I assume I’m safe and those around me are safe from me. It’s a reasonable thought. I am careful after all.

However, accidents by definition are quite literally “an unfortunate incident that happens unexpectedly and unintentionally, typically resulting in damage or injury.” And as I was reminded recently, they can happen even when we do everything write.

So what spooked me so badly that I was inspired to write about safety?

Although I don’t do much tech work nowadays, I still have some colleagues that I’ll don my blacks for to help out in a pinch. And I’ve done lighting long enough that I can hang a stage wash blindfolded. This particular day, a good friend was down an ME so I offered to lend a hand for a decent-sized social event in San Francisco. Among the tasks on my hit list was to hang two dozen lekos from schedule 40 trees to be focused with breakups for room ambiance.

As is my protocol...

• I pulled and sorted the gear and spread it to install locations.

• I inspected the fixture body and lens tube, looking for cracks or accumulation of dust;

• I gave the instrument a little shake to make sure the reflector wasn’t smashed;

• I inspected the whips for fraying and the plugs for loose blades or weak connections;

• I tightened the yolk, drop-in Iris door, c-clamp bolts and inspected the inner and outer adjustment knobs;

• I ensured each instrument had a safety cable, a working gel frame, and frame clip, and the shutters operated properly.

• I also inspected the dimmer packs, the 12-3 stinger, the crossbar, the upright, and the base.

• I made sure I had adequate beach for ballast, e-tape to dress cables;

It doesn’t take long, but this is a habit of mine, so I’m thorough. This wasn’t an insection I learned out of a book. It developed over time, the result of problems I’ve faced in the past. And everything looked fine. I was ready to hang.

So I set the pole grabbed a ladder and secured my c-wrench using a tie-line as a lanyard, in case I happened to drop it. I asked someone close by to foot the ladder and I ascended in a manner consistent with OSHA-approved ladder use. Everything was safe, by the book, what could go wrong? Everyone around me was moving at a safe pace and obeying the standards described in the OSHA-10 certification program.

Well, that’s when something went wrong. I just finished tightening the c-clamp and was going to start dressing the cables, when my e-tape slipped out of my fingers. Since it’s only e-tape, I didn’t put a lanyard on it, so it fell harmlessly to the ground. I took my hands off the instrument I was working on and took a step down the ladder. That’s when I heard a loud crack and saw a bright flash in my periphery. I jerked my head back just in time to see the light emit a series of follow-up flashes - the whip had come apart at the base of the instrument and it was shorting and arching, scorching the instrument every time it came in contact.

Fortunately, I didn't hesitate and I covered my face while I reached up over the whip doing its little dance and pulled the plug from the dimmer. Since I was below the dimmer and the whip was between us, I had to extend and arc over the hot cable to keep it from being burned. Catastrophe averted, but once it was over I stood in shock for a minute. I had just had both hands on this instrument that was energized only a split second after I moved my hands.

I didn't do anything wrong and I didn’t miss a step or take a shortcut. It was simply an unforeseen circumstance - an accident. I’m fortunate there was no significant damage and no injury. But let this serve as a reminder to everyone we work with:

• Be aware of your surroundings, always.

• Keep your head on a swivel

• Avoid distractions and stay focused.

• Don’t get complacent and remember, when we stop being safe, the price we can pay is far more than we’re willing to pay.

• And be nice to your QC team at the shop. They have a harder job than we realize sometimes. And their extra attention can definitely save your life.

Stay safe! Cheers…