Stage rigging load monitoring system

Monitor every lifting point in real time with Ron StageMaster™, a scalable wired and/or wireless load monitoring system developed for concerts, touring productions, theaters, arenas and other entertainment-rigging applications.

Ron StageMaster combines fatigue-rated load cells, central receivers and proprietary monitoring software to display the measured load at every rigging point on a live stage-plan layout. Rigging teams can identify uneven load distribution, monitor dynamic load changes, configure warning thresholds and record measurement data during setup, performance, and teardown.

Key capabilities:

• Monitor up to 200 load cells per monitoring station

• Combine wired and wireless load cells in one system

• View the entire rig on a real-time load map

• Measure with accuracy of up to ±0.1% of full range

• Configure visual, audible and SMS overload alerts

• Connect programmable set points to control systems

• Record and download continuous measurement data

• Choose load-cell capacities from 1 ton up to 300 tons

• Support temporary, touring, and permanent installations

• Five-year warranty

Modern stage rigging is more complex and dynamic than ever

Modern stage productions suspend more equipment, across more lifting points, than ever before. Large LED walls, lighting grids, moving scenery, audio systems, video cubes, special effects, and flying performers can create rigs involving dozens or even hundreds of interconnected lifting points.

The challenge is not simply the total suspended weight.

Modern stage rigging is also highly dynamic. Scenery moves, video elements rise and descend, performers accelerate and stop, and environmental forces may affect outdoor structures. These movements can change the load carried by individual hoists and suspension points throughout an event.

A rig may therefore appear balanced while one point is carrying substantially more load than expected.

This problem is closely connected to the engineering principle of a statically indeterminate structure. When a structure is supported by multiple lifting points, its load distribution cannot always be established through visual balancing or simple calculations alone. Small differences in truss deflection, cable length, hoist position and structural stiffness can produce significant differences between the loads at individual points.

As stage rigs become heavier and more complex, relying on assumptions or visual leveling creates a dangerous uncertainty. Rigging teams need measured, real-time information about what’s happening at each lifting point.

And that’s the role of a stage rigging load monitoring system.

What Is stage rigging?

Stage rigging is the equipment, engineering, and working methods used to hoist, suspend, support, and move production elements during a live performance or entertainment event.

A stage rig may include:

• Trusses, beams, and support structures

• Chain hoists and lifting motors

• Wire ropes, slings, shackles, and pulleys

• Lighting fixtures and lighting grids

• Audio and audiovisual equipment

• LED screens and video walls

• Curtains, backdrops, and scenic elements

• Props and special-effects equipment

• Flying performers and aerial apparatus

These elements may be installed temporarily for a single event, transported as part of a touring production, or permanently integrated into a theater, arena, studio, or convention center.

Because equipment and people may be suspended above workers, performers, and audiences, accurate load information is an essential part of professional rigging planning and operation.

Why load distribution is a critical stage rigging challenge

Knowing the total weight of a suspended structure does not necessarily reveal how that weight is distributed between its lifting points.

For example, a truss suspended from several hoists may look perfectly level while one hoist carries a disproportionate part of the load. The difference may be caused by small variations in the structure, rigging geometry, or hoist positions that are not visible from the ground.

Statically indeterminate structures

A structure becomes statically indeterminate when there are more unknown load reactions than can be solved using basic equilibrium equations alone.

In practical stage-rigging terms, this commonly occurs when a beam is supported by more than two hoists or when a three-dimensional structure is supported by more than three points.

Under these conditions, the load carried by each point depends not only on the total suspended weight but also on factors such as:

• Structural stiffness and deflection

• Hoist and support-point positioning

• Variations in sling or cable length

• The location of individual production elements

• Changes made during installation

• Movement during the performance

• Dynamic acceleration and deceleration

Without direct measurement, the actual load at each point may remain unknown.

Dynamic loads

A static load remains relatively constant while the rig is stationary. A dynamic load changes because of motion, acceleration, deceleration or impact.

Dynamic forces may be created by:

• Moving video screens or scenic elements

• Flying performers and aerialists

• Rapidly operated hoists

• Sudden starts and stops

• Rotating or tilting structures

• Wind acting on outdoor stages and screens

• Changes to the rig during the performance

The load at a specific point can temporarily rise above its normal static value during these movements. Monitoring load solely during installation may therefore provide an incomplete picture.

But continuous load monitoring allows the rigging team to see how loads change while the rig is raised, operated, and lowered.

What is a stage rigging load monitoring system?

A stage rigging load monitoring system measures the force at individual lifting or suspension points and presents the measurements to the rigging team in real time.

Load cells are installed at selected points within the rig. Each load cell measures the load passing through it and sends the measurement to a receiver or monitoring station.

The monitoring software then presents the measurements on a single interface. In a multi-point system, the measurements can be positioned over the production’s stage plan so operators can immediately identify the physical location of each monitored point.

Instead of relying only on estimated equipment weights or theoretical calculations, the rigging team can see the measured load carried by each point.

This information can support:

• Load balancing during installation

• Verification of individual rigging points

• Detection of unexpected load changes

• Monitoring during movement

• Overload and underload alerts

• Motor-control or emergency-stop integration

• Documentation and post-event analysis

• Long-term monitoring in permanent venues

How the Ron StageMaster load monitoring system works

The Ron StageMaster provides a complete multi-point stage rigging load monitoring environment, combining load cells, receivers, and monitoring software.

1. Install load cells at the rigging points

Load cells are installed at the relevant suspension or lifting points within the rig.

Depending on the application, the system may use:

• Eilon Classic tension load cells

• Shackle-pin load cells

• Wired load cells

• Wireless load cells

• A combination of wired and wireless devices

• Different capacities within the same system

The correct load-cell type and capacity should be selected according to the rigging design, available headroom, required safety factor, and anticipated loading conditions.

2. Measure every monitored point

Each load cell continuously measures the load passing through its position.

In a wireless system, each load cell transmits its measurements independently to the central receiver. A wired system communicates through a single-cable architecture connected to the monitoring station.

Because each point is measured individually, the operator can compare the actual load distribution across the rig rather than seeing only the combined total.

3. View the rig on a live load map

Ron StageMaster software can display the monitored lifting points over the production’s stage-plan layout.

The operator can see:

• The current measurement at every point

• The total load

• Maximum recorded values

• Defined groups of load cells

• Warning and overload conditions

• Low-battery indications

• Changes in load distribution

Displaying the measurements in their physical locations helps the rigging team understand where an imbalance or overload is developing.

4. Configure alerts and control actions

Operators can establish individual or grouped thresholds according to the requirements of the rig.

Depending on the selected configuration, the system can provide:

• Visual overload warnings

• Audible alarms

• Underload alerts

• SMS notifications

• Programmable set-point outputs

• Integration with motor-control or emergency-stop systems

The appropriate control response should be defined by the production’s qualified engineering and rigging personnel.

5. Record and analyze measurement data

Ron StageMaster can record continuous load data for later review.

Logged measurements can help production and venue teams:

• Review load changes during an event

• Investigate unusual measurements

• Compare repeated installations

• Document monitored loads

• Identify recurring imbalance patterns

• Support maintenance and engineering decisions

Key benefits of the Ron StageMaster for stage rigging

Real-time multi-point load monitoring

The Ron StageMaster displays the measured load at every monitored lifting point rather than relying on total weight alone.

The system supports up to 200 load cells per PC or laptop monitoring station. Additional stations can be used across larger venues or separate operating zones.

Continuous, always-on monitoring

The wireless Ron StageMaster system is designed for continuous transmission without relying on a sleep or standby mode during monitoring.

Standard wireless configurations provide up to 5,000 hours of battery life with a transmission rate of once per second. There’s also an optional configuration offering up to 10,000 hours.

Continuous monitoring is especially valuable where loads may change after installation, including moving stage elements, long-running productions, and permanent venue systems.

Wireless, wired, and hybrid configurations

Different productions require different communication methods.

Wireless load cells can reduce cabling and simplify installation for touring productions, temporary stages, and frequently changing rigs.

Wired systems are well suited to permanent venues and fixed installations where a stable cabling infrastructure can be installed.

Ron StageMaster can also combine wired and wireless load cells, allowing the system to accommodate complex venue layouts or mixed temporary and permanent monitoring points.

Live stage-plan visualization

A numerical list may show the measurements, but a graphical load map makes those measurements easier to interpret.

Ron StageMaster can position each load cell over a visual representation of the rig. Operators can therefore connect an abnormal measurement directly to its physical location.

Large systems can also be divided into groups, each with its own monitoring thresholds and visual layout.

High-accuracy load measurement

Eilon Classic load cells are available with accuracy of up to ±0.1% of full range.

Accurate measurement helps rigging teams identify relatively small differences between lifting points and monitor changes during setup or operation.

The required load-cell capacity should be selected carefully, since appropriate sizing is an important part of achieving useful measurement resolution.

Fatigue-rated load cells

Ron StageMaster load cells are fatigue-rated for applications involving repeated load cycles.

This makes them particularly suitable for:

• Permanent theater installations

• Arenas and convention centers

• Long-running productions

• Repeated touring use

• Moving and dynamic rigging elements

All equipment must still be operated within its specified working-load, safety-factor, and environmental limits.

Scalable system architecture

A system can begin with a relatively small number of monitored points and expand as operational requirements grow.

Load cells of different capacities and configurations can be incorporated into the wider Ron StageMaster environment, allowing the system to support both compact productions and major multi-zone venues.

Remote alerts and control integration

Depending on the selected system and accessories, operators can configure remote SMS notifications and connect programmable outputs to visual alarms, audible alarms, or compatible control systems.

This allows abnormal conditions to be communicated quickly to the relevant production personnel.

Choose the right stage rigging load monitoring configuration

There is no single configuration that is ideal for every stage rig. The appropriate system depends on whether the installation is temporary or permanent, the number of lifting points, available headroom, communication requirements and expected load range.

Wireless Ron StageMaster system

A wireless system is typically suited to:

• Touring concert productions

• Temporary event installations

• Rental companies

• Outdoor festivals

• Frequently changing stage layouts

• Applications where extensive signal cabling is undesirable

Wireless load cells transmit independently to the central receiver and can be repositioned as production requirements change.

Ron StageMaster 6000G5 Wireless Load Monitoring System

Wired Ron StageMaster system

A wired system is typically suited to:

• Permanent theaters

• Arenas and stadiums

• Convention centers

• Studios and broadcast facilities

• Long-term structural monitoring

• Fixed installations with established cable routes

The wired Ron StageMaster 5000 uses a single-cable communication architecture and provides continuous real-time monitoring for permanent and mission-critical applications.

Ron StageMaster 5000 Wired Load Monitoring System

Hybrid wired and wireless systems

Some venues require a combination of permanent and temporary monitoring.

For example, a theater may use wired load cells for its fixed infrastructure while adding wireless load cells for a visiting production. A convention center may use separate technologies in different halls or operating zones.

Ron StageMaster systems can combine wired and wireless load cells, different capacities, and multiple monitoring stations within a broader monitoring environment.

Eilon Classic load cells

Eilon Classic tension load cells are designed for quick installation and accurate multi-point measurement.

They are available in multiple capacities and are suitable for a wide range of entertainment-rigging applications.

Eilon Classic Load Cells

Shackle-pin load cells

Shackle-pin load cells replace a standard shackle pin with an instrumented pin that measures the applied load.

Their low-headroom configuration can be particularly useful where adding a conventional tension load cell would increase the overall height of the rigging assembly.

Ron StageMaster Shackle-Pin Load Cells

Stage rigging applications

Concerts and touring productions

Touring productions must install, operate, and dismantle complex structures repeatedly across different venues.

Rigging conditions may change from one venue to another, even when the production equipment remains the same. Roof capacities, support locations, local geometry, and available rigging points may all affect the final configuration.

Wireless stage rigging load cells allow touring teams to monitor actual loads during installation and throughout the event without creating an extensive permanent cabling system.

Theaters and performing arts venues

Theaters may contain counterweight systems, motorized scenery, lighting bridges, acoustic elements, curtains and performer-flying systems.

A wired or hybrid monitoring system can support permanent infrastructure while also accommodating changing productions.

Continuous monitoring is especially relevant where equipment moves during performances or where a venue hosts many different visiting productions.

Arenas, stadiums, and convention centers

Large venues may support concerts, exhibitions, corporate events, broadcasts, and sporting productions, each with different rigging requirements.

A scalable system allows the venue or production team to monitor many lifting points, organize them into separate groups and use additional monitoring stations where required.

Broadcast and television productions

Television and broadcast rigs may suspend lighting, camera equipment, video screens, scenic elements, and temporary studio infrastructure.

Load monitoring helps production teams verify the distribution of these elements and observe changes during rehearsals and live operation.

Circus and aerial performance

Circus productions and aerial performances introduce dynamic forces created by moving performers and apparatus.

The load measured during movement may differ significantly from the static suspended weight. Continuous measurement gives operators a clearer picture of how individual rigging points behave throughout the performance.

Outdoor festivals and temporary structures

Outdoor productions may be exposed to changing environmental conditions in addition to movement within the rig.

Load monitoring does not replace structural engineering, weather monitoring or an approved operational plan, but it can provide additional real-time information about the forces measured at selected rigging points.

Ron StageMaster technical capabilities

The specifications below describe commonly available Ron StageMaster configurations. Final specifications depend on the selected load-cell model, capacity, communication system and optional accessories.

Request Technical Specifications  

Proven in real-world stage rigging applications

The Ron StageMaster was introduced for entertainment-industry load monitoring in the mid-2000s and has since been used in touring productions, permanent venues, and large-scale entertainment structures.

Classic Eilon load cell using in a Cirque du Soleil production

Cirque du Soleil

Cirque du Soleil began using Ron StageMaster systems for sophisticated big-top productions in 2007.

Real-time measurement gave the production team reliable load data for complex aerial and structural elements. According to the original project information, the system also improved installation efficiency by reducing the time required to suspend and level the cupola from approximately one hour to around 15 minutes.

The measurements allowed the team to make decisions based on observed load distribution rather than relying only on conservative estimates.

Cirque du Soleil Load Monitoring Case Study

Metallica world tours

Ron StageMaster load cells have been used on multiple Metallica touring productions.

During the WorldWired Tour, the system monitored a dynamic installation involving 52 rapidly moving LED video cubes.

For the M72 World Tour, load cells were used in connection with large video structures installed within approximately 100-foot towers. These applications demonstrate the importance of monitoring loads that may change during operation rather than measuring only the static rig before the performance.

Metallica Stage Rigging Load Monitoring Case Study

Orange County Convention Center

Stage rigging load monitoring is not limited to productions using hundreds of load cells.

In 2022, the Orange County Convention Center used 12 Ron StageMaster load cells for LED screens suspended above a stage. The measurements allowed the team to verify the distribution of the supported load across the monitored points.

This type of configuration demonstrates how multi-point monitoring can also be applied to smaller temporary rigs.

Orange County Convention Center Case Study

Bristol Motor Speedway

The Colossus at Bristol Motor Speedway is a large center-hung LED display suspended above the venue.

Ron StageMaster shackle-pin load cells were selected for the installation to monitor loads while minimizing additional headroom within the rigging arrangement.

The low-headroom load cells supported precise load management during installation of the halo truss and circular LED structure.

Bristol Motor Speedway Load Monitoring Case Study

Other productions and venues

Ron StageMaster systems have also been used in connection with major concert tours, broadcast productions, entertainment venues and international events, including projects involving Paul McCartney, Aerosmith, and Eurovision.

Each production presents a different combination of load capacities, rigging geometry, movement and monitoring requirements. The modular system can be configured according to the number of points, communication method and operating environment of the specific project.

What real-world experiments reveal about hidden rigging loads

To examine how suspended loads behave under practical conditions, Eilon Engineering collaborated with Sapsis Rigging on a series of load-monitoring experiments using real rigging equipment.

The experiments examined factors including:

• Multi-point load distribution

• Truss leveling

• Multiple-hoist configurations

• Multi-level grids

• Movement and dynamic forces

• Sudden acceleration and deceleration

The measurements demonstrated that a structure can appear level while the actual load distribution remains significantly uneven.

They also illustrated how changes at one point can affect other lifting points within a statically indeterminate structure. Adding more hoists does not automatically produce a more even distribution; in some arrangements, it makes the load behavior more difficult to predict without direct measurement.

Dynamic tests further demonstrated that moving elements can produce short-duration forces that exceed their static weight. Sudden stops, changes in direction and rapid movement can increase the measured load at individual points.

The practical conclusion is not that calculations are unnecessary. Engineering calculations remain a fundamental part of rigging design.

However, calculations and visual observations do not provide continuous information about the actual load at each point during installation and operation. Real-time load monitoring adds measured data to the rigging team’s planning, inspection and operational procedures.

Why rigging professionals choose the Ron StageMaster

Developed specifically for multi-point load monitoring

Ron StageMaster is not simply a collection of independent measuring devices. It is designed as a complete monitoring system for applications in which multiple lifting points must be viewed and managed together.

Proven wireless load-monitoring experience

Eilon Engineering has developed wireless load measurement technology since 1976 and introduced its first multi-point systems in the mid-2000s.

The Ron StageMaster system has since been used by touring productions, performing arts organizations, venues and technical production teams around the world.

Flexible load-cell and receiver options

The system can be configured using different:

• Load-cell capacities

• Safety factors

• Wired and wireless communication methods

• Receiver types

• Monitoring stations

• Alert outputs

• Software layouts

• Data-logging options

This allows the system to be adapted to both temporary entertainment rigs and permanent venue installations.

Engineering support

Selecting a stage rigging load monitoring system requires more than choosing the number of load cells.

The configuration should consider:

• Maximum expected load at each point

• Required measurement resolution

• Safety factor

• Wireless or wired communication

• Transmission distance

• Available headroom

• Environmental conditions

• Required alert functions

• Control-system integration

• Number of venues or monitoring zones

Eilon Engineering can assist with selecting the appropriate load cells, receivers and monitoring configuration for the application.

Stage rigging load monitoring FAQ

What role do load cells play in stage rigging?

Load cells measure the force at individual suspension or lifting points. In a multi-point stage rigging system, the measurements allow operators to see how the suspended load is distributed across the rig.

This helps rigging teams verify load balance, observe changes and identify points approaching their defined operating thresholds.

Why is multi-point load monitoring important?

The total suspended weight does not show how much load is carried by each hoist or support point.

In a statically indeterminate structure, the distribution may be uneven even when the rig appears level. A multi-point monitoring system measures the individual points and displays the complete distribution in real time.

How do dynamic loads affect stage rigging?

A dynamic load changes because of acceleration, deceleration, movement or impact.

Moving scenery, video structures and aerial performers can temporarily increase the force measured at individual rigging points beyond the normal static load. Continuous monitoring allows operators to observe these changes while they occur.

How many load cells can the Ron StageMaster monitor?

A Ron StageMaster PC or laptop monitoring station can display up to 200 load cells.

Additional monitoring stations may be used for larger venues, separate halls or independent operating zones.

What is the difference between wired and wireless stage rigging load cells?

Wireless load cells transmit measurement data by radio, reducing signal cabling and making them especially useful for temporary and touring installations.

Wired load cells communicate through a cable system and are often selected for permanent or long-term installations.

Ron StageMaster can combine wired and wireless load cells where both technologies are needed.

Does wireless stage rigging monitoring require venue Wi-Fi?

The primary radio communication between Ron StageMaster wireless load cells and the relevant Eilon receiver does not depend on the venue’s general Wi-Fi network.

Specific mobile, web-based, or remote-access functions may have separate connectivity requirements depending on the selected configuration.

Can the Ron StageMaster monitor loads during a performance?

Yes. Ron StageMaster is designed for continuous real-time monitoring.

This allows the rigging team to observe load changes during setup, rehearsals, performances and teardown, subject to the production’s approved operating and safety procedures.

Can wired and wireless load cells be used together?

Yes. Ron StageMaster supports the integration of wired and wireless load cells within a broader monitoring system.

This can be useful for venues that have permanent monitored infrastructure but also need to accommodate temporary production elements.

Is Ron StageMaster suitable for permanent installations?

Yes. Wired systems and fatigue-rated load cells are particularly well suited to theaters, arenas, convention centers and other long-term installations.

The final configuration should be selected according to the venue’s engineering requirements, environmental conditions and monitoring procedures.

Can Ron StageMaster connect to a motor-control or emergency-stop system?

Programmable set-point outputs can be configured to interact with compatible controllers, alarms or emergency-stop functions.

The exact integration and response logic must be designed and approved by qualified personnel responsible for the rigging and control systems.

Can the system send overload alerts?

Depending on the selected configuration, Ron StageMaster can provide visual and audible warnings as well as real-time SMS notifications.

Thresholds can be assigned to individual load cells or defined groups.

Can load-monitoring data be recorded?

Yes. Data-logging options allow continuous measurements to be stored and downloaded for analysis.

The records can support post-event review, comparison between installations and documentation of monitored load conditions.

Which load-cell capacity should be selected?

The load cell must be selected according to the maximum expected load, required safety factor, potential dynamic forces and desired measurement resolution.

Using a substantially oversized load cell may reduce the practical resolution available for smaller loads. Eilon Engineering can recommend an appropriate capacity based on the application details.

How often should stage rigging load cells be calibrated?

The required calibration interval depends on the product, frequency of use, operating conditions, applicable procedures and local requirements.

Load cells should be inspected, maintained and calibrated according to the manufacturer’s instructions and the organization’s approved safety program.

What information is needed to configure a system?

To recommend an appropriate Ron StageMaster configuration, it is helpful to provide:

• Number of monitoring points

• Expected load range at each point

• Temporary or permanent installation

• Wired or wireless preference

• Required transmission distance

• Available headroom

• Indoor or outdoor environment

• Required warning and control functions

• Data-logging requirements

• A rigging plan or drawing, when available

Configure your stage rigging load monitoring system

Modern stage rigs are too complex to assess load distributions based on visual inspection alone.

The Ron StageMaster gives rigging professionals real-time measurement at every monitored point, helping them understand how loads are distributed, observe dynamic changes, and respond to abnormal conditions with greater confidence.

Tell our engineering team about your rig, including the number of suspension points, expected capacities and whether the installation is temporary or permanent. We’ll help you select the appropriate load cells, receivers, and monitoring configuration that best suits your needs.

Get in touch today