Truss lifts

Truss Lifts – Efficient Lifting Solutions for Professional Event Technology

Truss lifts are indispensable tools in professional event technology, enabling safe and efficient positioning of truss systems, lighting rigs, speaker arrays and stage equipment at working heights of up to 12 metres. Whether You are setting up a mobile stage, rigging a festival lighting installation or building a trade-fair stand, truss lifts provide the stable, height-adjustable support You need to achieve impressive results. At LTT, You will find a comprehensive range of manual and electric truss lifts from leading manufacturers, all certified to BGV C1 and DGUV 17 standards for use at events with public access.

What Are Truss Lifts and How Do They Work?

A truss lift — also known as a telescopic lift, wind-up stand or lifting tower — is a height-adjustable, free-standing support system designed to lift and hold truss structures and attached equipment safely in position. Unlike simple lighting stands, which are typically limited to 60 kg and designed for single luminaires, truss lifts are engineered to handle loads from 100 kg up to 2000 kg and working heights from 3.8 metres to 12 metres.

Telescopic vs Fork Lift Designs

Truss lifts are available in two fundamental design types. Telescopic lifts feature nested tube sections that extend vertically via a winch-driven cable or chain mechanism. The truss adapter — typically a 35 mm or 50 mm diameter spigot — is mounted at the top of the mast. Telescopic lifts are compact when collapsed (transport height typically 1.5–2 m) and offer excellent portability for mobile applications.

Fork lifts, by contrast, use a horizontal fork assembly that rises along a fixed or telescopic mast. The fork engages directly beneath the truss, allowing loads to be lifted from near ground level. This design is particularly advantageous when working with heavy 4-point truss systems or line-array speaker configurations, as it eliminates the need to manually raise the truss onto a top-mounted adapter. Fork lifts typically offer higher load capacities (up to 300 kg standard, 2000 kg heavy-duty) and are preferred for permanent installations and large-scale productions.

Both types are operated via a manual crank winch or, in heavy-duty models, an electric motor. A critical safety feature is the automatic locking system (ALS) or manual safety pin, which provides secondary securing against unintended movement in compliance with DGUV 17 requirements.

Applications – Where Truss Lifts Deliver Professional Results

Truss lifts are the backbone of efficient stage construction and event rigging. In mobile event production, they enable rapid setup and breakdown of lighting trusses, speaker towers and projection screens. A typical application involves positioning two truss lifts at either end of a horizontal truss span, creating a stable overhead grid for lighting fixtures, moving heads or LED panels.

In theatre and concert venues, truss lifts are used to rig follow-spot positions, side-fill speaker arrays and scenic elements. Their ability to hold loads safely at precise working heights makes them ideal for creating layered lighting designs and achieving the optimal "Wow effect" that captivates audiences.

Trade-fair and exhibition stands rely on truss lifts to support branding elements, product displays and AV equipment. The compact transport dimensions and quick setup times make them the optimum solution for exhibitors who need to build professional stands efficiently.

Outdoor festivals and open-air events demand robust, weather-resistant equipment. Heavy-duty truss lifts with extended outrigger bases and wind-load calculations ensure stability even in challenging conditions. When working outdoors, always consider lateral forces from wind and secure the entire truss structure with additional guy wires or ground anchors as required by DGUV 18.

For related rigging hardware and truss systems, explore the full range of professional stage construction equipment available at LTT.

Quality Standards and Professional Specifications – What to Look For

When selecting a truss lift, understanding the technical specifications and safety certifications is essential for professional application. Load capacity is the primary criterion: entry-level telescopic lifts typically handle 100–150 kg, mid-range models 200–300 kg, and heavy-duty fork lifts up to 2000 kg. Always account for the combined weight of the truss itself, attached equipment and cabling — a 3-metre length of aluminium box truss (e.g. Naxpro-Truss FD31) weighs approximately 8–12 kg per metre, while a moving head luminaire adds 15–25 kg.

Working Load Limit (WLL) ratings must be clearly stated and certified. All truss lifts used at events with public access in Germany and across Europe must comply with BGV C1 (now superseded by DGUV Vorschrift 17 for venues and DGUV Vorschrift 18 for temporary structures). These regulations mandate dual independent safety systems: typically a load-holding brake on the winch mechanism plus an automatically engaging safety pin or ratchet lock.

Working height determines application suitability. Standard models reach 4–6.5 metres, suitable for most indoor venues and mobile DJ setups. Festival and arena applications often require 8–12 metre lifts. Note that transport height (collapsed dimension) affects vehicle loading and storage — most professional models collapse to 1.5–2 metres.

Leading manufacturers in this category include Block and Block (European-made lifts with robust construction and TÜV certification), VMB (known for the patented ALS auto-lock security system) and Manfrotto (offering ergonomic winch designs). At LTT, You will also find models from Fantek, Work and Ultralite, all meeting the stringent safety standards required for professional use.

Adapter compatibility is crucial: 35 mm diameter spigots suit most 2-point and 3-point trusses, while 50 mm or 55 mm heavy-duty adapters are required for 4-point truss systems. Some lifts offer T-bar or fork adapters for greater versatility. Always verify that the adapter system matches Your truss connection standard.

Safety Systems and Certification – Understanding BGV C1 and DGUV 17 Requirements

The safety of truss lifts is governed by strict German and European standards. DGUV Vorschrift 17 (formerly BGV C1) specifies that all lifting equipment used in venues must be equipped with dual independent safety mechanisms to prevent unintended movement. In practical terms, this means a truss lift must have both a load-holding brake integrated into the winch mechanism and a secondary mechanical lock.

The load-holding brake — typically a friction disc or automatic pressure brake — engages whenever the operator releases the crank handle, preventing the load from descending under its own weight. However, mechanical components can fail, which is why a second safety layer is mandatory.

Automatic safety pins (also called ratchet locks or ALS systems) engage mechanically into pre-drilled holes or slots in the mast sections at regular height intervals. The VMB ALS (auto-lock security system) is a widely recognised example: as the mast extends, spring-loaded pins automatically engage into the next available locking position. This ensures that even if the winch cable breaks or the brake fails, the load is arrested within a few centimetres of travel.

Manual safety pins, while simpler, require the operator to insert a bolt by hand at each height increment. This approach is acceptable under DGUV 17 but places greater reliance on operator discipline and can lead to ergonomically awkward working positions, particularly when the operator must hold the pin open with one hand while cranking with the other.

Crucially, the wall thickness of the mast tubes must be sufficient to withstand the shear forces exerted by the safety pin under full load. Thin-walled tubes (below 2 mm) may deform or tear, rendering the pin ineffective. Professional-grade lifts use steel or aluminium profiles with wall thicknesses of 2–3 mm, manufactured to EN 10219 or EN 10305-5 standards.

All truss lifts at LTT are supplied with CE conformity declarations and, where applicable, TÜV certification. Regular inspection and maintenance — as mandated by DGUV — must be documented, and any lift showing signs of deformation, corrosion or mechanical wear must be withdrawn from service immediately.

Setup, Operation and Load Distribution – Practical Guidance for Safe Use

Correct setup and operation of truss lifts is essential for both safety and performance. Begin by selecting a level, load-bearing surface. Outrigger feet must make full contact with the ground; use load-distribution plates or wooden boards if working on soft surfaces such as grass or gravel. Most professional lifts include a spirit level (bubble vial) on the base — ensure the lift is plumb before loading.

Outrigger span varies by model but typically ranges from 1.75 m to 2.3 m diameter. Wider bases provide greater stability but require more floor space. When working in confined areas, consider using guy wires or additional bracing to the building structure, particularly for tall setups or outdoor applications subject to wind load.

When attaching the truss, distribute the load symmetrically. If using two lifts to support a horizontal truss span, position them equidistant from the truss centre of gravity. Uneven loading creates torsional stress and increases the risk of tipping. For 4-point truss systems, use fork adapters or T-bars that engage all four truss tubes simultaneously, ensuring even load transfer.

Lifting procedure: Operate the winch crank smoothly and steadily. Avoid jerky movements, which can shock-load the cable and mast sections. If using an automatic safety pin system, listen for the audible "click" as each pin engages — this confirms the secondary lock is active. On manual-pin models, insert and secure the pin at every available height increment; never skip positions to save time.

When lowering the load, maintain control of the crank handle at all times. The load-holding brake should prevent free-fall, but operator vigilance is critical. On manual-pin systems, disengage the pin only when You are ready to lower to the next position, and never stand directly beneath the load.

Load calculation must account for the truss self-weight, all attached equipment (luminaires, speakers, motors, cables) and dynamic forces. As a rule of thumb, add 20% safety margin to the static load to account for rigging operations and environmental factors. For complex setups involving multiple truss sections and heavy equipment, consult a qualified rigging engineer or refer to the manufacturer's load charts.

Integration with Naxpro-Truss systems is straightforward: the FD21 and FD31 series (2-point and 3-point trusses with 35 mm diameter tubes and 2 mm wall thickness) are compatible with standard 35 mm lift adapters. The HD31 and HD44 heavy-duty series (50 mm tubes, 3 mm wall thickness) require 50 mm or 55 mm adapters. Always verify adapter diameter and load rating before rigging.

LTT – Your Specialist for Event Technology

At LTT, You benefit from over 25 years of experience in professional event technology and stage construction. As both a leading distributor and manufacturer with our own production facility in Germany, we offer not only high-quality branded products but also in-depth technical expertise and reliable support.

Our truss lift range includes proven models from Block and Block, VMB, Fantek and Work, all certified to BGV C1 and DGUV 17 standards. Whether You need a compact 125 kg telescopic lift for mobile DJ applications or a heavy-duty 2000 kg fork lift for arena-scale productions, You will find the optimum solution in our portfolio. Every lift is supplied with comprehensive operating instructions, conformity declarations and safety documentation.

We ship worldwide from our logistics centre in Bocholt, Germany, with free shipping on orders over €69 within Germany and competitive rates for international delivery. Express shipping options are available for urgent projects. As a B2B supplier, we offer wholesale pricing for resellers and maintain an international dealer network for our own brands including Naxpro-Truss, Riggatec and Bullstage.

With over 100,000 positive customer reviews and a 3-year LTT warranty on selected products, You can rely on quality, service and professional advice. Our team of event-technology specialists is ready to help You select the right truss lift for Your application and ensure Your next production is set up safely and efficiently.

FAQ – Questions & Answers