1Understanding LED Rigging
LED wall rigging is the process of safely suspending or supporting LED video displays using structural hardware, safety factors, and proper load distribution. It encompasses weight calculations, point load analysis, hardware selection, and compliance with entertainment rigging standards (PLASA/ESTA) to ensure no structural failure occurs during installation or operation.
LED walls are heavy. A typical 20x12 foot touring wall using 2.9mm panels weighs approximately 3,500-4,500 pounds for panels alone—add truss, cables, and mounting hardware and you are quickly approaching 5,000+ pounds suspended overhead. Getting rigging wrong has consequences ranging from cancelled shows to catastrophic structural failure.
This guide covers everything production professionals need to safely rig LED walls. We focus on calculations, hardware, and decision-making rather than the physical act of rigging—that requires hands-on training and certification that no written guide can replace.
The Stakes of Getting It Wrong
LED rigging failures make headlines when they happen. A 2019 incident at a major festival resulted in a 15,000 pound LED wall collapsing when rigging hardware failed during setup. Fortunately, no audience was present. Similar near-misses happen regularly at events worldwide, usually due to calculation errors, inadequate hardware, or improper installation.
The costs extend beyond physical danger:
- Legal liability: Injuries from rigging failures result in lawsuits naming every party in the chain—rental companies, production companies, riggers, and venues
- Insurance: Inadequate rigging documentation can void coverage
- Equipment damage: A falling LED wall destroys $100,000+ of equipment instantly
- Career impact: Riggers and production managers involved in failures face career-ending consequences
The Two Approaches: Flying vs Ground Support
LED walls are either flown (suspended from overhead rigging points) or ground supported (standing on floor-based structures). Each approach has distinct requirements:
Flying (Suspended)
Wall hangs from venue rigging points via motors, truss, and rated hardware. Maximizes floor space but requires adequate ceiling structure and proper load calculations.
Ground Support
Wall stands on floor-based frames with ballast for stability. No overhead requirements but needs significant floor space behind the wall and proper weight distribution.
Critical Safety Notice
LED wall rigging must be performed by qualified riggers with appropriate training and certification. The calculations in this guide are for planning and verification—they do not replace professional engineering review for installations subject to structural codes or where public safety is involved.
2Weight Calculations
Accurate weight calculation is the foundation of safe rigging. Underestimating weight leads to overloaded hardware and potential failure. This section provides the formulas and methodology for calculating complete system weight.
Panel Weight: The Starting Point
Total Panel Weight = Number of Panels × Weight per PanelPanel weight comes from manufacturer specifications—never estimate or use averages. Panel weight varies significantly based on pixel pitch, construction, and manufacturer:
| Panel Type (Example) | Weight per Panel | 60-Panel Wall Weight |
|---|---|---|
| ROE Black Pearl BP2V2 (500mm) | 7.8 kg (17.2 lbs) | 468 kg (1,032 lbs) |
| Absen PL2.9 Pro (500mm) | 8.5 kg (18.7 lbs) | 510 kg (1,124 lbs) |
| ROE Carbon CB5 (600mm) | 12.0 kg (26.5 lbs) | 720 kg (1,587 lbs) |
| Unilumin UpadIII 2.6 (500mm) | 9.0 kg (19.8 lbs) | 540 kg (1,190 lbs) |
Hardware and Accessories Weight
Panel weight is only the beginning. Complete system weight includes:
- Bumper bars: Top rigging attachment bars (15-40 kg depending on wall width)
- Hanging hardware: Shackles, spansets, connectors (10-30 kg per wall)
- Power and data cables: Often 20-50 kg for a typical wall
- Corner braces/stiffeners: If used for curved or large walls
Rule of thumb: Add 15-20% to panel weight for hardware and cables. This provides a reasonable estimate when exact accessory weights are not available.
Truss Weight (If Applicable)
When flying LED walls from truss (rather than direct-to-venue points), include truss weight in calculations:
| Truss Type | Weight per Meter | 6m Span Weight |
|---|---|---|
| 12" (290mm) Box Truss | ~8 kg/m (17.6 lbs/m) | 48 kg (106 lbs) |
| 20.5" (520mm) Box Truss | ~14 kg/m (30.9 lbs/m) | 84 kg (185 lbs) |
| 30" (762mm) Box Truss | ~22 kg/m (48.5 lbs/m) | 132 kg (291 lbs) |
Complete Weight Calculation Example
Scenario: 10x6 Panel Wall (ROE BP2V2)
This weight is used for all subsequent rigging calculations. With a 5:1 safety factor, rigging hardware must support 3,160 kg (6,967 lbs) Working Load Limit across all pick points combined.
3Point Load Analysis
Point loads—the weight applied at each rigging attachment—determine whether venue rigging points and hardware can safely support your LED wall. Understanding how to calculate point loads, including the effects of bridle angles, is essential for venue approval and safety.
Basic Point Load Calculation
Point Load (basic) = Total Weight ÷ Number of Pick PointsExample: Our 632 kg wall from the previous example, hung from 4 pick points:
Point Load = 632 kg ÷ 4 = 158 kg (348 lbs) per point
This is the basic calculation assuming vertical hanging. Real-world installations often use bridles, which increase point loads significantly.
Bridle Angle Effects
A bridle connects multiple points on the load to a single suspension point above. Bridle angles dramatically affect the actual load on rigging points.
Actual Point Load = Basic Point Load ÷ cos(angle from vertical)| Bridle Angle (from vertical) | Load Multiplier | 158 kg Basic Becomes | Status |
|---|---|---|---|
| 0° (vertical) | 1.00× | 158 kg | Optimal |
| 15° | 1.04× | 164 kg | Excellent |
| 30° | 1.15× | 182 kg | Good |
| 45° | 1.41× | 223 kg | Acceptable Max |
| 60° | 2.00× | 316 kg | Dangerous - Avoid |
Critical: Never Exceed 45° Bridle Angles
At 60° from vertical, bridle legs carry double the basic load. Shallow bridle angles are a primary cause of rigging failures because hardware that appears adequate based on basic calculations becomes overloaded. Keep bridle angles below 45° from vertical—ideally under 30°.
Complete Point Load Example with Bridle
Scenario: 4-Point Bridle at 30° Angles
Uneven Weight Distribution
The calculations above assume weight distributes evenly across all points. Real walls may have:
- Asymmetric content sources: Heavier processors on one side
- Unequal pick point spacing: Points not centered on mass
- Curved configurations: Non-rectangular layouts
For complex configurations, use rigging software (VectorWorks, AutoCAD with rigging plugins) or consult a structural engineer. The formulas here apply to symmetric, rectangular walls with evenly spaced points.
4Rigging Hardware
Every component in the rigging chain must be rated for the expected load with appropriate safety factors. Using unmarked, unrated, or industrial (non-entertainment) hardware is never acceptable for overhead rigging.
Essential Hardware Components
Bumper Bars
Structural bars that attach to the top of LED panel arrays, providing rigging points. Manufacturer-specific—must match your panel type. Rated for specific maximum loads.
Shackles
Rated connectors joining rigging elements. Must show stamped WLL rating. Use bow shackles for multi-directional loads. Never use hardware-store shackles for rigging.
Spansets / Round Slings
Flexible synthetic slings for connecting rigging points. Available in various capacities (1-ton to 10-ton common). Color-coded by capacity. Inspect for cuts, abrasion, UV damage.
Steel / Wire Rope
Steel cables for permanent or high-load connections. Requires proper terminations (thimbles, ferrules). Higher capacity than spansets for same diameter.
Chain Hoists / Motors
Electric lifting devices for raising/lowering LED walls. Entertainment-rated with dual braking, overload protection. Capacities from 1/2-ton to 2-ton typical.
Working Load Limit (WLL) Requirements
Every piece of rigging hardware has a Working Load Limit (WLL)—the maximum recommended working load incorporating safety factor. For entertainment rigging:
- 5:1 minimum safety factor: WLL is breaking strength ÷ 5
- Never exceed WLL: Even briefly, even during setup
- All hardware marked: Legitimate hardware shows stamped/forged WLL
- Match entire chain: Weakest link determines system capacity
Hardware Sizing Example
For our 632 kg wall at 4 pick points:
Secondary Safety / Backup
Critical rigging often includes secondary attachments that take load only if primary rigging fails. These backup systems:
- Connect to a separate attachment point from primary
- Must be rated for full load (not reduced capacity)
- Should have minimal slack (catch load immediately if primary fails)
- Are often required by venues and insurance for overhead rigging
5Flying vs Ground Support
The choice between flying and ground support depends on venue capabilities, production requirements, and practical constraints. Each approach has distinct advantages and requirements.
When to Fly LED Walls
Flying (suspended installation) is preferred when:
- Floor space is limited: No room for ground support footprint
- Height is required: Wall must be elevated for sightlines
- Variable height needed: Motors allow repositioning during shows
- Venue has adequate rigging: Points and capacity available
- Clean aesthetic required: No visible support structure
When to Use Ground Support
Ground support (floor-standing) is preferred when:
- No rigging points available: Venue lacks overhead structure
- Ceiling capacity insufficient: Cannot support wall weight
- Quick setup required: Ground support often assembles faster
- Low height acceptable: Wall does not need significant elevation
- Outdoor/temporary location: No permanent structure above
Comparison Summary
| Factor | Flying | Ground Support |
|---|---|---|
| Floor space | Minimal footprint | 4-8 feet depth needed |
| Setup time | Longer (rigging phase) | Often faster |
| Height adjustable | Yes (with motors) | Fixed |
| Venue requirement | Rated rigging points | Adequate floor loading |
| Additional equipment | Motors, truss, rigging | Frames, ballast |
| Cost (typical) | Higher (motors) | Lower |
Ground Support Requirements
Ground support systems require specific considerations:
- Ballast: Weight to prevent tipping, typically 50-100% of wall weight
- Floor loading: Concentrated weight at base plates (verify venue capacity)
- Stability: Outriggers or wide base to prevent overturning
- Seismic/wind: Additional requirements for outdoor or earthquake zones
Ground Support Still Requires Engineering
Ground support does not eliminate structural concerns—it shifts them to floor loading, stability analysis, and ballast calculations. A falling ground-supported wall is just as dangerous as a falling flown wall. Follow manufacturer specifications exactly.
6Safety Requirements
Entertainment rigging operates under established safety standards that have been developed from decades of experience. Compliance with these standards is not optional—it is the baseline expectation for professional work.
Industry Standards
Entertainment rigging standards are developed by PLASA (Professional Lighting and Sound Association) and ESTA (Entertainment Services and Technology Association). Key standards include:
- ANSI E1.2: Entertainment technology - Design, manufacture, and use of aluminum trusses and towers
- ANSI E1.21: Entertainment technology - Temporary ground-supported structures
- ANSI E1.4: Entertainment technology - Manual counterweight rigging systems
- PLASA Technical Standards: Additional guidelines for entertainment rigging
Safety Factor Requirements
| Application | Minimum Safety Factor |
|---|---|
| Overhead rigging (entertainment) | 5:1 |
| Wire rope/steel cable | 5:1 to 7:1 |
| Permanent installations | 8:1 or per code |
| Ground support structures | 5:1 (2:1 for stability) |
Required Qualifications
LED wall rigging requires trained, experienced personnel:
- Riggers: Formal training in entertainment rigging (ETCP certification is industry standard)
- Crew: Understanding of rigging principles and safety procedures
- Supervision: Competent person overseeing all rigging operations
- Engineering review: Required for complex or high-load installations
Inspection Requirements
Before Each Use
- • Visual inspection of all hardware
- • Verify WLL markings legible
- • Check for damage, deformation, wear
- • Inspect slings for cuts, UV damage
- • Test motor operation before loading
Periodic / Annual
- • Detailed hardware examination
- • Motor load testing and certification
- • Truss inspection for cracks, fatigue
- • Documentation review and update
- • Retire aged or worn equipment
7Venue Coordination
Venues have their own rigging capabilities, limitations, and approval processes. Successful LED wall installations require early communication and documentation.
Information Venues Need
- Point loads: Weight at each rigging point in pounds/kilograms
- Point locations: Where you need to attach (X/Y in venue coordinates)
- Total system weight: Complete weight of wall, truss, and rigging
- Attachment method: How you will connect to their points
- Rigging plot: Drawing showing complete rigging layout
Common Venue Limitations
- Point capacity: Maximum load per rigging point (often 500-2,000 lbs)
- Total capacity: Maximum combined load on grid or area
- Point spacing: Fixed grid spacing may not match your needs
- Height limits: Maximum trim height or headroom constraints
- Advance requirements: Days/weeks notice for rigging calls
Working with House Riggers
Many venues require using their in-house riggers or approved contractors:
- Request venue rigging plot showing available points and capacities
- Submit rigging documentation in advance (often 2+ weeks)
- Coordinate timing for rigging calls
- Be prepared for venue-specific requirements or approvals
- Budget for house rigging labor in production costs
Document Everything
Maintain written records of weight calculations, venue communications, rigging plots, and equipment specifications. This documentation protects you legally and helps troubleshoot problems. Many venues require rigging documentation for insurance purposes.
8Common Mistakes to Avoid
These mistakes occur regularly in the field and have led to equipment damage, injuries, and deaths. Learn from others' errors.
Underestimating wall weight
Consequence: Overloaded hardware, potential structural failure
Use manufacturer specs exactly, add 15-20% for hardware, never estimate
Ignoring bridle angle effects
Consequence: Point loads 1.4-2× higher than calculated, hardware failure
Calculate actual loads including angle factors, keep angles under 45°
Using unmarked or unrated hardware
Consequence: Unknown capacity, no legal protection, likely failure
Only use entertainment-rated hardware with visible WLL markings
Skipping secondary safety attachments
Consequence: Complete failure if primary rigging fails
Install rated backup connections on all critical loads
Not verifying venue capacity
Consequence: Venue rejection of rig, structural damage, show cancellation
Request venue rigging plot, submit documentation in advance
Inadequate ballast for ground support
Consequence: Wall tips over from wind, vibration, or accidental contact
Follow manufacturer ballast requirements exactly, often 50-100% of wall weight
Rushing rigging during load-in
Consequence: Missed inspections, improper connections, accidents
Build adequate rigging time into schedule, never shortcut safety checks
9Decision Framework
Use this framework to plan LED wall rigging systematically. Following these steps in order prevents common problems.
The Rigging Planning Checklist
- 1Calculate total system weight
Panels + bumpers + hardware + cables + truss (if applicable). Use manufacturer specs.
- 2Determine flying vs ground support
Based on venue capabilities, floor space, height requirements, and production needs.
- 3Calculate point loads with bridle angles
Divide weight by points, then multiply by angle factor. Keep angles under 45°.
- 4Apply safety factors
All hardware must have WLL ≥ 5× actual point load.
- 5Verify venue capacity
Confirm point locations and capacities match your requirements.
- 6Select and spec hardware
Shackles, spansets, motors—all entertainment-rated with documented WLL.
- 7Create rigging documentation
Rigging plot, weight calculations, hardware specs, venue approvals.
- 8Inspect all equipment before use
Visual check of every piece of hardware, verify ratings, look for damage.
Calculate Rigging Requirements Automatically
Show Tech calculates total weight, point loads, and hardware requirements for any LED wall configuration. Enter your panels and get complete rigging specifications.
10Frequently Asked Questions
How do I calculate the total weight of an LED video wall?
Multiply the number of panels by the weight per panel from manufacturer specs. Add 15-20% for mounting hardware, cables, and frames. Example: 60 panels at 8kg each = 480kg for panels, plus 96kg for hardware, totaling approximately 576kg (1,270 lbs). Always use manufacturer specs, not estimates.
What safety factor should I use for LED wall rigging?
Use a minimum 5:1 safety factor for entertainment rigging (PLASA/ESTA standards). This means hardware with 5,000 lb Working Load Limit (WLL) can safely support 1,000 lbs of actual load. Some jurisdictions and venues require 8:1 or higher for permanent installations or public assembly.
How do bridle angles affect rigging point loads?
Steeper bridle angles (closer to vertical) are safer and put less load on hardware. At 30 degrees from vertical, loads increase by 15%. At 45 degrees, loads increase by 41%. At 60 degrees from vertical, loads DOUBLE. Never exceed 45 degrees from vertical for LED wall rigging.
When should I use ground support instead of flying an LED wall?
Use ground support when: venue lacks adequate rigging points, ceiling structure cannot support the load, quick setup is required, or installation is temporary and low-height. Ground support requires adequate floor space (4-8 feet behind wall) and proper ballast—typically 50-100% of wall weight.
What rigging hardware do I need to fly an LED wall?
Essential hardware includes: bumper bars (attach to top panels), shackles (rated connectors), spansets or steel cables (load-bearing connections), chain hoists or motors (lifting devices), and truss (if not hanging directly from venue points). All hardware must be entertainment-rated with documented WLL.
How do I calculate point loads for venue rigging approval?
Divide total wall weight by number of pick points for basic calculation. Then adjust for bridle angles using the formula: Point Load = (Weight / Points) / cos(angle from vertical). Always account for uneven weight distribution and apply safety factors. Venues typically require point loads, locations, and total system weight.
What is the difference between dead-hang and motorized flying?
Dead-hang uses static rigging (spansets, shackles, steel) to fix the wall at a set height—simpler and less expensive but height is not adjustable during shows. Motorized flying uses chain hoists for height adjustment during events and easier load-in/load-out. Motors cost $3,000-8,000 each but provide significant flexibility.
How much floor space does ground support require?
Expect 4-8 feet of depth behind the LED wall for support frames, plus outrigger footprint for stability. A 20-foot wide wall might need 24x10 feet total footprint. Add space for ballast (water barrels, sand bags, or steel weights). Always check manufacturer specifications for your specific support system.