MATERIAL HANDLING HAZARDS
SETTING UP LARGE-SCALE VIDEO EQUIPMENT
In the events industry, the use of fast-fold screens for displaying images from projectors has been around for more than 30 years. Fast-fold screen setups involve tall structures that require coordination between crew members to ensure the screen is put up safely.
Large-scale LED builds are now becoming more common in the events industry, especially for larger events, such as concerts and trade shows. Additionally, the film industry has also started to use LED panels to create a substitute for the “green screen” method of filming special effects and animation. These large structures take weeks to months to build, have a lot of moving parts and can weigh many thousands of pounds. The task of setting up an LED wall can be dangerous if proper precautions are not taken.
Safety protocols and sound communication methods must be in place when setting up LED structures and fast-fold screens.
Before you start the task, COMMUNICATE!
FAST-FOLD SCREENS
Putting Up and Taking Down Large Fast-fold Screens
Safety Issue:
When setting up fast-fold screens in smaller breakout rooms, the risk of injury is lower compared to building larger fast-fold screens in larger spaces. Slips, trips and overhead work hazards are serious safety concerns, especially when building a frame to hang from a truss structure or erecting larger sized fast-fold structures from the ground up.
Safety Protocol:
STEP 1: Clear out an area on the ground large enough to build the screen. Make sure you know the height of the screen and if the dress kit is the appropriate size.
STEP 2: Take all the parts necessary to build the skeletal structure of the screen out of its case and assemble it, including putting the legs on the frame.
STEP 3: Stretch and attach the designated screen onto the frame.
STEP 4: Add on any valence package that might be needed.
STEP 5: Look up! Make sure that the screen is not going to hit any overhead objects (e.g., chandeliers, bulkhead) that can cause damage to the venue or equipment, and of greater concern, injury to yourself or your crew. If dismantling, communicate with the crew and get a consensus on the method of “bringing down the surface”.
STEP 6: Lift the screen.
Before lifting the screen, make sure the backs of the legs are fully extended as this will be what you step on to anchor the screen as you lift it up vertically.
The size of the screen will determine how many people will be needed to lift it into place. If the screen is larger than 9.5’ by 16’, it is recommended that you have someone at the base of each leg to pin it with downward force to prevent the screen from sliding forward once you start to lift the screen. Two people, one on either side of the screen, will then lift the screen in the centre (where the weight is evenly distributed) and walk it up while stepping along the backs of the legs that are still on the ground.
STEP 7: Once the screen is sitting vertically in place, lock the backs of the legs off to the structure and put the cranks in place.
HANDLING LED PANELS
Passing LED Panels and Associated Equipment
Safety Issue:
When passing LED panels (to someone on a ladder, someone in a scissor lift or someone working within the LED structure) the following safety issues are present:
- A worker can overextend/overreach in a harmful way when passing a panel to someone on a ladder. The worker on the ladder can fall if not maintaining 3 points of contact with the ladder while passing/receiving panels.
- Someone can be struck by a panel if dropped from a height.
- The edges of LED panels are thin and sharp and can cut you if handled improperly.
Safety Protocols:
A) PASSING LED PANELS TO SOMEONE ON A LADDER
STEP 1: Reach in the case or bin and grab the LED panel using the top handle. Remove the panel from the case carefully and slowly. Always handle the panel with the pixels facing away from your body to avoid any potential damage to the pixels by way of clothing fibers catching on them.
Remember your PPE! Whenever there is any exposure to overhead work that can cause a head injury, you must wear a hard hat.
In a typical LED build, hard hats must be worn by workers in three situations:
- Workers on the ground passing LED panels up to workers on ladders or scaffolding platforms when there is a risk that the panel may fall from a height that can cause head injury.
- Workers working at heights (scissor lift, scaffold or ladder) who are exposed to overhead hazards (truss lines, rafters, beams, hanging light fixtures, etc.)
- All workers on the ground who are exposed to any overhead work hazards
As a general rule, when an LED structure will be over 8 feet in height upon completion, staff working on the ground should wear their hard hats.
STEP 2: Get in position to pass the panel. Position yourself as close to the ladder as possible and make eye contact with the worker who will be receiving the panel.
STEP 3: Pass the panel using the side handles to allow for the worker on the ladder to grab the panel from the top handle.
Communicate! Check that the worker receiving the panel has control over the panel before letting go. Use words/phrases like “passing to you”, “panel is ready” or “’it’s yours.”
If you are the worker on the ladder, move slowly and maintain 3 points of contact with the ladder. In this case, your 3 points of contact may include two feet and part of your body leaning against the ladder if you are using two hands to receive and place the panel on the LED wall. As soon as you receive the panel and have a secure grip on it, communicate with the worker passing the panel to you that it is okay to let it go. Use phrases like “got it”, “mine” or “you can let go”.
Never overextend yourself passing or receiving panels to save time going up or down an extra step on the ladder. Shortcuts cause injuries!
| NOTE: A double-stacked case of LED panels is too tall and too heavy to manually unstack. Using a forklift or the liftgate of a truck can be useful to help unstack these cases. In some situations, if the LED structure is on an elevated stage, the double stack can be placed against the stage so that panels can be removed from the top case without unstacking. |
B) PASSING LED PANELS TO SOMEONE IN A SCISSOR LIFT
Place panels gently in the lift, and if possible, on a soft surface like a moving blanket or foam pad. Some panels also come with a foam cover to protect the panel. If this is the case, keep the cover on the panel while it is stored in the lift.
Safety precautions that should be top of mind when completing this task include:
- Only load as many panels into the lift as the operator can install while still having room to move freely inside the lift.
- When loading any supporting gear (bridge clamps, cheeseboroughs, fastening clamps, etc.) into the lift, make sure nothing is partially hanging over the edges to prevent anything from falling out.
- Make sure any cables are secured to the lift or coiled in the lift to prevent any potential falling hazard (secure the cable off with rope or tape the cable to a part of the lift).
- Everyone in a ground supporting role should be wearing a hard hat as a precaution.
C) PASSING LED PANELS TO SOMEONE WORKING WITHIN THE LED STRUCTURE
In this situation, both workers are working at heights, on a ladder and/or scissor lift, on either side of the LED structure.
This task requires strong communication between two workers, one who is outside the LED structure and one within, to prevent injuries that can result from pinch point hazards while handling the panels. The worker in the front/outside of the LED structure should hold the weight of the panel while the worker in the back of the structure places the panel and locks it in place.
| What is a pinch point? A pinch point is where two objects come together and a body part, most commonly the fingers and hands, can get caught. |
SUMMARY
The larger the size of the fast-fold screen, the bigger the safety risk. Pay careful attention to your surroundings, giving plenty of space to build the frame and assess for overhead hazards prior to lifting the screen into place.
Always plan out your next steps when it comes to passing LED panels. Do you have the right amount of space needed to take the panel out of the case? Can you rest the panel somewhere without damaging it if needed?
Communicate! When you lift a panel to pass to a crew member on a ladder, lift or within a structure, speak to each other to confirm who has control over the panel. If you have the LED panel, say something like “passing to you” and if you are receiving the panel, once you have the panel securely, say something like “mine” or “I’ve got it now”
This Health and Safety Blog was written by Cavan Sladen, Crew Chief and Certified JHSC Worker Representative at Crew Supply Inc. Cavan has extensive experience supervising large crews and is Crew Supply’s key person for workplace and safety inspections. He has a passion for health and safety and serves as Co-chair on Crew Supply’s Joint Health and Safety Committee.