Ron StageMaster™ – Real-Time Load Monitoring for Safe, Complex Stage Rigging

The growing challenge of modern stage rigging

Modern stage rigging has become incredibly complex, with total suspended loads getting heavier every year.

But it's not just a matter of weight—stage rigging is also more dynamic than ever. And all those moving parts add more than entertainment—they also increase the risk to performers and audiences.

Modern stage rigging's complexity is linked to the engineering principle of statically indeterminate structures. 

These are structures where you can’t evenly distribute the weight just by balancing the loads visually, due to the way materials naturally flex and bend. This makes calculating the true load distribution an arduous task.

So even if the loads on a truss look balanced, some lifting points may be dangerously overloaded. Add moving elements into the equation, and you can see how quickly the challenge grows.

What is stage rigging?

Simply put, stage rigging is the system of equipment and techniques used to hoist, suspend, and move elements of a live stage production or entertainment event. 

These elements include:    

• Ropes, pulleys, trusses, and hoists
• AV equipment
• Scenery, curtains, and backdrops
• Props and special effects
• Flying performers and acrobats
  
  

With several tons of equipment suspended directly above audiences, stage rigging is serious business.

Riggers face multiple challenges, like shifting dynamic loads, wear and tear on hardware, and unpredictable environmental conditions. But perhaps most vital is the challenge of precise load distribution.

As noted above, when multiple points are hung on a truss, the weight isn’t always shared evenly, even if the loads appear to be balanced.

In the past, riggers could get away with simple “rule of thumb” guesses. But with today’s complex stage rigs, guessing isn’t good enough. 

That leaves two options. The first is to perform detailed calculations, accounting for how forces are distributed across trusses and hoists, how support structures deform when under load, and how dynamic stage elements shift during movement.

This approach is complex and labor-intensive, and risks even a small miscalculation putting the entire structure at risk of collapse. 

Fortunately, there is a better, simpler, and safer option.

How the Ron StageMaster solves is all

The second option comes down to two words: load monitoring. It’s both simple to execute and affords the highest level of safety. When riggers know the precise weight of every lifting point, in real time, there’s no guesswork.

But how can rigging teams incorporate load monitoring into rigs both large and small? The solution is the Ron StageMaster load monitoring and overload prevention system.

Combining load cells, remote receivers, and proprietary software, the Ron StageMaster provides operators with a live-event load mapping system that displays the weight of every lifting point.

It’s designed for both straightforward, smaller rigs, and large, complex dynamic rigs. With customizable alerts and instant visual feedback, the Ron StageMaster is the easiest way to ensure the safety of your stage rigging: no risky calculations, no guesswork.

Ron StageMaster key features:

• Real-time load mapping across up to 200 points
• Wireless + wired compatibility
• Long battery life (up to 8,000 hours of continuous monitoring)
• ±0.1% accuracy, fatigue-rated ASME BTH-1 load cells
• Compliance: LRQA audited, decades of expertise
• Mobile compatibility & SMS alerts

Proven in action: real-world applications

Launched in 2006, the Ron StageMaster has a long and proven track record of reliable performance in real-world conditions: from touring shows to permanent installations. 

Over the past two decades, countless performances have benefited from the safety that only multi-point wireless load monitoring for stage rigging offers.

From massive shows with hundreds of load cells, to smaller rigs with just a few, the Ron StageMaster has become a must-have piece of stage rigging equipment for riggers around the globe.

Here are some highlights from over the years:

Cirque du Soleil

Since 2007, Cirque du Soleil has relied on the Ron StageMaster for both safety and efficiency in its sophisticated big top productions. The hard data provided by the RSM allowed the team to safely add production elements that might have otherwise been ruled out due to guesswork.

Time savings was another benefit, as real-time monitoring reduced the time it took to suspend and level the cupola from an hour down to 15 minutes.

https://crm.eilon-engineering.com/uses/projects/cirque-du-soleil/ (this one is not on the new site)

Metallica

The RSM has been used on many major world tours, including those by Metallica. In the WorldWired Tour, RSM load cells were a critical component as 52 high-speed ascending and descending LED video cubes added a dynamic element.

More recently, on the M72 World Tour—one of the heaviest and largest touring rigs ever—RSM load cells were used to monitor the massive video walls in 100-foot-tall towers.

https://crm.eilon-engineering.com/uses/projects/metallica-2023/ (not on the new site)

Orange County Convention Center

Not all stage rigging involves a massive setup with 100+ load cells—safety is just as important on smaller rigs.

In 2022, the Orange County Convention Center used Ron StageMaster load cells to support several LED screens suspended above the stage.

With 12 RSM load cells in place, the team verified weight distribution to maintain a stable and secure rig.

https://www.eilon-engineering.com/pages/orange-county-convention-center 

Bristol Motor Speedway

The Colossus at Bristol Motor Speedway is the world’s largest center-hung LED display, weighing nearly 700 tons and suspended by 117 tons of cabling. 

To ensure precise load management during installation, Ron StageMaster shackle pin load cells were used to minimize headroom loss while supporting the massive halo truss and circular LED ring. 

The result is a feat of engineering that delivers over 10,500 square feet of high-resolution, immersive viewing for spectators.

https://crm.eilon-engineering.com/?item=1886&section=82 (not on the new site)

Other shows

Over the past few years, we’ve seen the Ron StageMaster used with major tours such as Paul McCartney and Aerosmith. It was even used at the 2025 EuroVision where 90+ RSM load cells were used, including two 85-ton load cells for the ground support towers.

RSM vs. other systems

The Ron StageMaster isn’t just the oldest and most established load monitoring system specifically designed for stage rigging, it’s also the top performing system. 

Here’s how it stacks up:

Understanding load challenges: real-world experiments

To better understand the challenges and dangers inherent in stage rigging, Eilon Engineering, in collaboration with Sapsis Rigging, conducted a series of experiments using real-world equipment and conditions. 

The goal was to shed light on how loads actually behave when suspended, moved, or adjusted, and to understand the potential for hidden overloads.

The experiments showed that even when a structure appears to be level with evenly balanced loads, significant imbalances can occur, with one lifting point suddenly taking on more weight than intended. It also demonstrated that having multiple hoists or a multi-level grid amplified the problem.

The experiments further highlighted the risks of dynamic forces, such as those involved with moving elements, like aerial performers. For instance, when rigging elements make sudden stops or changes in speed, a load can be multiplied well beyond its static weight, exceeding safety limits by wide margins.

The findings make it clear that outdated estimation methods and visual leveling simply aren’t good enough for today’s level of dynamic, complex stage rigging. 

Only continuous, stage rigging load monitoring can provide riggers with the precise information required to keep crews, performers, and audiences safe.

Learn more about statically indeterminate structures in stage rigging.

Stage rigging FAQ

What role do load cells play in modern stage rigging?

As part of a larger wireless fatigue-rated load cell monitoring system, load cells ensure loads are evenly distributed, prevent dangerous overloads, and give riggers the data they need to rig safely and confidently.

How do dynamic loads affect stage rigging safety?

Dynamic loads such as aerial performers and scenery, can create forces greater than a load's static weight when they move. These movements cause spikes in the weight of certain rigging points, which can lead to dangerous overloads.

Why is a load monitoring system vital for multi-point stage rigging?

In multi-point rigging, weight must be distributed evenly across multiple lifting points. A stage safety load monitoring system shows the exact weight distribution, helping prevent dangerous overload by detecting them before they occur.

How does the Ron StageMaster differ from other solutions?

The Ron StageMaster stands out for its wireless, real-time monitoring, long battery life, and proven track record of exceptional quality. Further, unlike other systems, it’s designed for continuous use with no sleep mode, ensuring constant protection during events.

Is the Ron StageMaster suitable for U.S. venues and long-term installations?

Yes. The Ron StageMaster meets U.S. standards and is widely used in arenas, theaters, and stadiums. Its long battery life and fatigue rated load cells make it ideal for long-term installations.

What are the most common stage rigging mistakes beginners should avoid?

Avoid improper load calculations, using incorrect knot types or hardware, neglecting safety checks, poor communication, and ignoring equipment guidelines.

Trusted across industries & continents

The Ron StageMaster is used in a wide range of sectors, including:

• Live events & touring shows: major concert productions, festivals, and world tours
• Broadcast & TV: high-profile productions like the MTV Video Music Awards and Eurovision
• Performing arts venues: permanent installation in theaters, arenas, and cultural centers
• Circus & aerial performance: big-top productions like Cirque du Soleil and other complex aerial performances
• Aerospace: the Ron CraneMaster was used the joint NASA/Boeing’s CST-100 Starliner spacecraft project

Ready to take control of your rigging safety?

With today’s dynamic and complex stage rigging, guesswork isn’t good enough. Safe rigging now requires a level of precision that only real-time load monitoring can provide. 

Raise your rigging confidence and cut uncertainty out of the equation.