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Fly systems - counterweight line sets, motorised and automated flying, and dead-hung pipe grids, designed, supplied, installed and serviced by Theatre Safe Australia, Australia wide

Lifting & Rigging · Fly Systems

If it flies above your stage, we've got it.

A fly system is the overhead rigging that flies your scenery, drapes and bars in and out - counterweight line sets, motorised hoists, or a dead-hung grid. We design, supply, install and service the lot, so you can run the show and leave the load to us.

See what's in a fly system

Or call 1300 439 872

Flown on stages and in venues around Australia
HOTA Home of the Arts Canberra Theatre Centre Brisbane Powerhouse Ipswich Civic Centre Gold Coast Convention and Exhibition Centre Brisbane Showgrounds Arts Queensland WA Department of Local Government, Sport and Cultural Industries National Gallery of Victoria Cairns Convention Centre Melbourne Olympic Park Griffith University Queensland University of Technology University of Melbourne University of Adelaide Logan City Council Mackay Regional Council Wollongong City Council Mueller College Anglican Church Grammar School
What a fly system is

Overhead rigging,
that flies your show.

A fly system is the overhead rigging that flies scenery, drapes, lighting bars and backdrops in and out above a stage. On a counterweight system, each batten of gear hangs on a line set of wire lift lines, balanced against stacked weights on a cradle so an operator can haul it in by hand and hold it on a rope lock. On a motorised system, powered hoists do the lifting from a control desk.

The bar your gear clamps to is the fly bar or batten; the short ropes that suspend a dead-hung bar from the structure above are droppers. Every bar is rated to a working load limit (WLL), spread as a uniform distributed load across its length. We design, supply, install and service all of it, and keep it certified.

Manual counterweight line sets Motorised & automated hoists Dead-hung pipe grids WLL rated & certified AS 1418 / 4991 aligned
Counterweight line set · how it flies

Single purchase · 1:1. The arbor travels the full batten distance and carries an equal counterweight. The simplest set, but it needs a tall counterweight run behind the wall.

A side-section blueprint of a counterweight flying line set. Wire lift lines run from the batten up over the loft blocks and the head block, then down to a counterweight arbor that rides the locking rails. An operating line with a rope lock lets one operator fly the bar by hand. Toggle between single purchase, where the arbor travels the full batten distance, and double purchase, where the lift lines reeve through a sheave on the arbor so it travels half the distance and carries double the counterweight. Drag the slider to fly the bar in and out. GRID / LOFT STAGE DECK LOCKING RAILS BATTEN TRAVEL BALANCE 1:1 ARBOR TRAVEL FULL C-WEIGHT ×1 ARBOR TRAVEL · FULL
Flown out Flown in

Flies in and out on a loop - drag to scrub

Hover a part - or drag the slider to fly the bar in and out.

The rope lock holds the set where you leave it. It is the part an operator touches most. We design, install, balance and service every component shown here, and our fly system inspection grades each one against discard criteria.

Design to recertify, one team

Your fly system,
start to finish.

Rigging, hoists, control and soft goods are all in-house, so one team carries your fly system from the first drawing to the annual certificate. No subcontract chain, one point of accountability.

Design & documentEngineered fly plans and certified load documentation, sized to your stage and what you fly.Specify
SupplyCounterweight gear, powered hoists, control and soft-goods tracks, stocked and specified to suit.Supply
Install & commissionFitted, balanced, load-tested and commissioned, with the as-built paperwork to back it.Deliver
Train & hand overYour operators trained on the system and its safety features, so the team runs it inside designed limits.Operate
Service & recertifyScheduled inspection and servicing that keeps every line set safe and certified, year on year.Maintain

One team. One point of accountability.

Tell us what your stage flies and where it is in its life - new fit-out, upgrade, or a system that needs servicing - and we'll take it from there.

Or book a Systems Health Check

New to fly systems? Click through one in our Venue Rigging Explorer. Or explore the parts that make it up: chain hoists, pile hoists, controllers and curtain tracks. Already installed? The fly system inspection grades every line set, and the Service & Inspection Programme keeps it certified with scheduled visits.

FAQ

Questions
about the fly system.

If your question isn't here, call us or send your stage detail - we'll come back with the right answer for your room.

Call 1300 439 872
A fly system is the overhead rigging that flies scenery, drapes, lighting bars and backdrops in and out above a stage. It can be a manual counterweight system of line sets, a motorised or automated system of powered hoists, or a fixed dead-hung pipe grid, and is usually a mix of these across one venue.
A counterweight fly system balances each load against stacked weights on a cradle, so an operator hauls the set in and out by hand on a line set. A motorised system uses powered chain or wire hoists run from a control desk, and can be automated to play back cues. Many venues run both.
Operating an installed fly system is competency-gated, not licence-gated. Operators need training on that specific system and its safety features, but no High Risk Work Licence to run it. Rigging work, such as attaching loads, can be licensed depending on the task and your state. We train and hand over so your team runs day to day inside designed limits.
Yes. We design, supply and install new counterweight and motorised systems, and upgrade or motorise existing fly towers and pipe grids - from a single line set to a full system - then commission and certify the result.
Powered and load-bearing flying equipment should be inspected at least annually, with electric chain hoists load-tested and certified for 12 months. Our fly system inspection grades every line set against discard criteria.
Start with your stage

You run the show.
We've got the load.

Tell us what your stage flies and where your system is in its life - new fit-out, upgrade or service. We'll help you scope it, design and install it, and keep it certified - here and Australia wide.

Book a Systems Health Check