Safety ropes

Safety Ropes and Catch Ropes – Professional Stage Safety

Safety ropes and catch ropes are indispensable components of professional event safety. These secondary securing devices protect people and equipment from falling objects in theatres, clubs, trade shows and live events. At LTT, you will find high-quality safety ropes from Riggatec® and other trusted manufacturers – engineered to meet DGUV Vorschrift 17 (formerly BGV C1) and designed for reliable performance in demanding professional applications. Whether you are rigging moving lights on truss systems, securing loudspeakers or mounting effect equipment, our safety ropes deliver the peace of mind you need to focus on creating impressive shows.

What Are Safety Ropes and Catch Ropes?

A safety rope – also known as a catch rope or secondary securing device – is a wire rope designed to prevent equipment from falling if the primary mounting fails. Under DGUV Vorschrift 17 (the successor to BGV C1), all movable lighting, audio and rigging equipment in event and production venues must be secured by two independent devices: the primary mounting (such as a coupler, C-clamp or shackle) and a secondary safety rope.

Safety ropes consist of galvanized steel wire rope constructed to DIN EN 12385-4 (6 × 19 strand with fibre core) with a minimum tensile strength of 1770 N/mm². Both ends are fitted with thimbles (wire rope loops) to prevent kinking and to accept quick connectors, shackles or carabiners. The rope must be attached in such a way that the maximum fall height does not exceed 20 cm – or just 5 cm when securing equipment to moving lamp hangers – to limit impulse forces during a fall event.

Why Wire Rope – and Why No Plastic?

Plastic-coated cables and synthetic materials are not permitted for secondary securing. High temperatures – from lamp housings, nearby pyrotechnics or even fire – can cause plastic to soften or melt, rendering the safety device ineffective. Uncoated galvanized steel wire rope remains reliable across a wide temperature range and can be visually inspected for wear, corrosion or damage. Any rope that has been shock-loaded or shows visible damage must be retired immediately and replaced.

Safety ropes differ from general-purpose suspension ropes or lifting slings in that they are dimensioned to absorb dynamic impulse forces when a load falls into the rope. The tables in DGUV Information 215-313 specify the correct cable diameter and connector size for every equipment weight and rope length, ensuring that the safety factor remains well above the statutory minimum even under worst-case conditions.

Legal Requirements and Standards for Safety Ropes

The legal foundation for secondary securing in Germany is §7 of the former BGV C1 (now DGUV Vorschrift 17), which mandates protection against falling objects in event and production environments. This regulation applies to all movable equipment – including spotlights, moving heads, effect devices, loudspeakers, truss sections, mirror balls, monitors and projection equipment – that is suspended or mounted above areas accessible to people.

Core Regulatory Requirements

• Two independent securing devices: The primary mounting (coupler, clamp, shackle) and the secondary safety rope must function independently. If one fails, the other must hold the load.
• Maximum fall height: The safety rope must be attached so that the equipment cannot fall more than 20 cm. For moving lamp hangers and pantographs, the limit is 5 cm to protect the hanger mechanism from excessive impulse forces.
• No plastic materials: Wire rope, thimbles and connectors must be made of metal. Plastic-coated cables are prohibited because heat can compromise the coating and hide corrosion underneath.
• Suitable attachment points: The rope must be fastened to load-bearing points on both the equipment and the support structure. Handles, decorative features or non-structural parts are not acceptable attachment points.
• Inspection and replacement: Any safety rope that has been shock-loaded – even once – or shows visible signs of wear, kinking, corrosion or broken strands must be taken out of service immediately.

Relevant Standards

• DIN EN 12385-4: Specifies the construction and properties of wire rope (6 × 19 strand, galvanized steel, 1770 N/mm² tensile strength).
• DIN 56927: Defines the design and breaking load of quick connectors used in stage rigging.
• DGUV Information 215-313: Provides detailed dimensioning tables, installation guidance and examples for secondary securing in event technology.

These standards ensure that safety ropes are engineered to withstand not just the static weight of the equipment but also the dynamic impulse force generated when a falling object is suddenly arrested. Professional riggers rely on these tables to select the correct cable diameter, connector size and rope length for every application, ensuring compliance and safety on every project.

Choosing the Right Cable Diameter and Load Capacity

Selecting the correct safety rope is straightforward when you follow the dimensioning tables in DGUV Information 215-313. The table specifies the maximum equipment weight that each cable diameter can safely secure, taking into account the rope length and the impulse forces that occur during a 20 cm fall.

Load Capacity Table (Extract)

How to use the table: Weigh your equipment (including mounting bracket and accessories), then select the smallest cable diameter whose capacity exceeds your equipment weight for the rope length you intend to use. For example, a 12 kg moving head requires a 4 mm rope if you use a 60 cm length, or a 3 mm rope if you use a 100 cm length and the weight stays below 9 kg – but the 4 mm variant offers a greater safety margin and is the recommended choice.

Why Longer Ropes Have Higher Capacity

A longer rope stretches more during a fall, absorbing energy over a greater distance and reducing peak impulse force. This is why a 100 cm rope can safely hold almost twice the weight of a 60 cm rope of the same diameter. However, longer ropes also increase the potential fall distance, so always choose the shortest practical length that allows secure attachment and keeps the fall height below 20 cm.

Common Lengths and Applications

• 60 cm ropes: Ideal for compact fixtures mounted close to the truss, where space is limited and fall distance can be minimized.
• 100 cm ropes: Suitable for larger equipment, fixtures mounted on drop arms or pantographs, and situations where the attachment point is further from the primary mounting.

Always verify that the quick connector or shackle matches the cable diameter specified in the table. Using an undersized connector compromises the entire safety chain, even if the rope itself is correctly dimensioned.

Riggatec® Safety Ropes – German Engineering and Quality

Riggatec® is LTT's premium brand for professional rigging accessories, and our safety ropes exemplify the quality and reliability that event technicians expect. Manufactured in Germany, Riggatec® safety ropes are engineered to meet and exceed the requirements of DGUV Vorschrift 17, DIN EN 12385-4 and DIN 56927, delivering consistent performance across thousands of rigging cycles.

What Sets Riggatec® Apart

• Precision manufacturing: Every rope is assembled with galvanized 6 × 19 wire rope, pressed thimbles and connectors that meet exact dimensional tolerances. The result is a safety device you can trust in every installation.
• Complete range: Riggatec® safety ropes are available in cable diameters from 3 mm to 10 mm, in both 60 cm and 100 cm lengths, and in galvanized (silver) or powder-coated (black) finishes. This ensures you always have the right rope for your equipment weight and aesthetic requirements.
• Tested and certified: Each batch is produced to DIN standards and carries the technical documentation required for professional use. Riggatec® ropes are used daily in touring productions, permanent installations and broadcast studios across Europe.
• Value for professionals: Riggatec® combines German engineering quality with competitive pricing, making it the preferred choice for rental companies, rigging contractors and venue operators who demand reliability without compromise.

Comparing Riggatec® to Entry-Level Alternatives

While budget safety ropes may meet the letter of the regulation, professional riggers appreciate the difference that precision manufacturing makes. Riggatec® thimbles are cleanly pressed and sized to accept standard connectors without play or binding. The wire rope itself is consistently uniform, with no stray strands or rough spots that could snag or abrade during installation. And because Riggatec® is manufactured in-house at LTT's German facility, quality control is rigorous and traceability is guaranteed.

For touring productions where equipment is rigged and de-rigged daily, for permanent installations where safety ropes remain in place for months, and for high-profile events where failure is not an option, Riggatec® safety ropes deliver the peace of mind that comes from knowing your secondary securing is engineered to the highest standard.

Installation Guidelines and Attachment Best Practices

Correct installation of safety ropes is just as important as choosing the right diameter. Even a perfectly dimensioned rope will fail to protect if it is attached incorrectly or routed in a way that increases fall distance or creates stress concentrations.

Step-by-Step Installation

1. Identify suitable attachment points: On the equipment side, use the dedicated safety eyelet or structural mounting point specified by the manufacturer. Never attach the rope to handles, cable glands, decorative trim or non-load-bearing parts. On the support structure side, attach to the truss chord, a certified rigging point or a shackle – never to a coupler screw or other part of the primary mounting.

2. Select the correct connector: Use a quick connector (per DIN 56927), screw-gate carabiner or shackle that matches the cable diameter in the DGUV table. The connector must be captive (cannot open accidentally) and must fit through both the equipment eyelet and the support-structure attachment point.

3. Minimize fall distance: Route the rope so that if the primary mounting fails, the equipment drops no more than 20 cm before the rope becomes taut. For moving lamp hangers, pantographs and other articulated mounts, the limit is 5 cm. Avoid slack, loops or routing over sharp edges.

4. Inspect before every use: Check the wire rope for broken strands, kinks, corrosion or abrasion. Inspect thimbles for deformation and connectors for cracks or wear. If any component shows damage, replace the entire rope.

5. Document and label: In permanent installations, label each safety rope with its installation date and rated capacity. Maintain a log of inspections and replacements to demonstrate compliance during safety audits.

Common Mistakes to Avoid

• Attaching to the primary mounting: The safety rope must be independent. Clipping it to the same coupler or clamp that holds the fixture defeats the purpose of secondary securing.
• Excessive fall distance: A 50 cm fall generates impulse forces far beyond the design limits of the rope and can damage both the equipment and the support structure.
• Using damaged ropes: A rope that has arrested a fall – even a minor one – has absorbed energy and may have internal damage invisible to the eye. Retire it immediately.
• Improvised connectors: Cable ties, wire, string and improvised hooks are not acceptable. Use only connectors that meet the standards and are dimensioned per the DGUV table.

By following these guidelines, you ensure that your safety ropes function as intended, protecting your team, your audience and your equipment throughout the life of every installation.

Application Scenarios – From Touring to Permanent Installations

Safety ropes are used wherever event equipment is suspended or mounted above accessible areas. The specific requirements vary by application, but the underlying principle remains the same: two independent securing devices, minimal fall distance, and regular inspection.

Touring Productions and Live Events

In touring environments, equipment is rigged and de-rigged daily, often under time pressure and in varying venue conditions. Safety ropes must be robust enough to withstand repeated handling, quick to install, and easy to inspect. Riggatec® ropes in 60 cm and 100 cm lengths are the standard choice for moving heads, PAR cans, effect fixtures and loudspeakers mounted on truss grids. Black powder-coated ropes are popular for their discreet appearance under stage lighting.

Theatres and Permanent Installations

In fixed installations – theatres, concert halls, broadcast studios – safety ropes may remain in place for months or years. Here, corrosion resistance and long-term reliability are paramount. Galvanized Riggatec® ropes offer excellent durability, and the 100 cm length accommodates fixtures mounted on drop arms or adjustable hangers. Regular inspection schedules (quarterly or biannually) ensure that ropes are replaced before wear becomes critical.

Trade Shows and Corporate Events

Exhibition stands, product launches and corporate events often feature suspended signage, lighting and AV equipment. Even though these installations are temporary, DGUV Vorschrift 17 applies in full. Safety ropes must be dimensioned for the actual equipment weight, attached to certified rigging points, and inspected by qualified personnel. LTT supplies trade-show contractors with pre-assembled rope kits that include the correct cable diameter, connectors and documentation for fast, compliant installations.

Mobile DJs and Small Venues

Even in smaller venues – clubs, bars, mobile DJ setups – the principle of secondary securing applies. A 10 kg moving head mounted on a lighting stand or truss section requires a 4 mm safety rope (60 cm length). The investment is minimal, but the protection is absolute: if a clamp loosens or a stand tips, the rope prevents the fixture from falling onto the dance floor.

Across all these scenarios, LTT provides the safety ropes, connectors and technical guidance you need to meet regulatory requirements and protect everyone involved in your events.

LTT – Your Specialist for Event Technology and Rigging Safety

LTT has been supporting event professionals for over 25 years with high-quality equipment, in-house manufacturing and expert technical advice. Our Riggatec® brand represents the best of German engineering – precision-made rigging accessories that meet the exacting standards of touring productions, permanent installations and broadcast studios worldwide.

When you order safety ropes from LTT, you benefit from free shipping on orders over €69, express delivery options for urgent projects, and a 3-year LTT warranty that underscores our confidence in the quality of every product we sell. Our warehouse in Bocholt, Germany, holds extensive stock across the full range of cable diameters and lengths, so your order ships fast – often the same day.

Whether you are rigging a festival main stage, equipping a theatre fly system or securing a single moving head in a club, LTT is your reliable partner for professional event technology. Explore our complete range of rigging accessories, truss systems and stage equipment, and experience the difference that comes from working with a specialist who understands your world.

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