THEATRE COUNTERWEIGHT SYSTEMS

At ITE, we specialise in designing, supplying and installing high-quality theatre counterweight systems for performing arts venues across Australia. Our solutions are engineered for safety, smooth operation and long-term reliability—whether you're upgrading an existing fly system or building a new stage from the ground up.

While theatre technology continues to evolve, counterweight rigging systems remain the foundation of most new and existing performing arts venues. These systems offer proven reliability, flexibility, and tactile control for stage crews. In fact, many modern venues now incorporate hybrid systems, blending traditional counterweight linesets with newer technologies—but the core counterweight infrastructure remains essential.

From schools and community theatres to major performing arts centres, we custom-build each system to suit the unique demands of the space. We collaborate with venue managers, architects, and consultants to deliver fully compliant, user-friendly systems that support both day-to-day operation and professional-level productions.

What’s Included in a Counterweight System?

We supply and install all the critical components needed for a complete, safe and efficient counterweight system, including:

Cradles – traditional side-loading and front-loading cradles – also known as arbors

Pulleys– head pulleys, loft pulleys, and bottom return (tension) pulleys – also known as blocks

Guides – including wall frames, guide shoes, and cradle buffers

Rope locks – high-quality rope locks for safe operation at the lock rail

Lineset Board – high quality traditional chalkboards, whiteboards or digital versions

Lift Lines & Terminations – cut to length Steel Wire Rope with machine swaged terminations

Hauling Lines – available in manila, hempflax, and synthetic in 18mm–24mm diameters

Counterweights – standard 6kg and 12kg weights or custom weighted to suit project

Battens – including our Multipurpose Truss Batten, LX Ultra Lighting Bar, and traditional flat truss, 75x50 or 48OD steel pipe

Batten / barrel clamps – for safe connection and adjustment – also known as rigging irons

Safety mesh systems – for added protection around loading galleries and cradles

Line loks – Spaghetti looking locking systems to temporarily lock off the hauling line – sometimes confused with Rope Locks

Whether you're building from the ground up or upgrading an existing rigging setup, we’ll ensure your counterweight system is built for performance, safety and longevity.

Cradles

  • We supply and install both traditional top-loading and modern front-loading counterweight cradles, tailored to suit your venue’s rigging requirements and access conditions. Standard cradle systems support load capacities from 300kg to 500kg, with expansion cradles available to increase the load capacity of single linesets as needed. All cradles are generally designed to equal the self-weight of the lineset batten.

  • All cradles are fabricated in-house by qualified ITE metal fabricators and MIG welded for strength and long-term durability. They come finished in standard black and are assembled using high-tensile fasteners with nyloc nuts to ensure secure, vibration-resistant performance. Each cradle features custom-engineered top and bottom plates for reliable attachment of lift lines and hauling lines.

  • Front-Loading vs Side-Loading Cradles
    Front-loading cradles offer improved safety and ease of use. Weights are loaded from the front at a lower height, reducing the risk of manual handling injuries. Each cradle is also fitted with spring-loaded retaining covers, which confine the weights during operation, significantly lowering the risk of dislodgement or falling weights — especially in the event of a runaway cradle.

  • Side-loading cradles, while more traditional, are still widely used and include top stops to prevent counterweights from being ejected if the arbor were to overrun its travel.

Front Loading Cradle

Side Loading Cradle

Pulleys

We supply a full range of pulleys as part of our counterweight systems — all custom-engineered and built in-house at our Port Melbourne workshop using Australian steel and components.

Head Pulleys

Built tough, made to last, and designed for safe, smooth operation — just like the rest of our rigging hardware.

Here is what included:

  • 🔩

    Head pulleys – 300mm diameter, mounted at the top of the cradle to guide lift lines

  • 📐

    Loft pulleys – 200mm diameter, used to direct lines out to battens

  • ⚙️

    Bottom return pulleys – 200mm diameter, maintain tension where low trim heights are needed

  • 🎭

    Guide pulleys – optional, used to divert lines for things like panorama bars or special rigging setups

    • All pulleys feature:

  • 🛠️

    Keepers to keep wire ropes and hauling lines securely in their grooves

  • ⚙️

    Sealed-for-life bearings – smooth, quiet operation with no ongoing maintenance

  • 🔩

    High-tensile bolts and nyloc nuts – built to stay tight and secure under load

  • 🗜️

    Custom beam clamps – designed to suit any steel structure, whether it’s I-beams, C-channel, or grid-mounted systems

Cradle Guides

Our guide systems keep cradles running smoothly, safely, and accurately. We supply and install guide components tailored to suit both modern and traditional counterweight systems.

  • Here’s what we provide:
  • 🎯

    Wall-mounted wall frames – usually constructed from Unistrut to ensure the guides are mounted true and level despite wall inconsistencies

  • 🔧

    Guide shoes – fitted to each cradle to glide smoothly within the wall guides

  • ✔️

    Cradle buffers – usually constructed from timber and mounted at the top and bottom of the cradle run to prevent over-travel

  • Additional notes:
  • 🎯

    Modern systems use guide shoes instead of rollers for better alignment and reduced maintenance

  • 🔧

    We can still supply roller guide assemblies to suit traditional guide rails if required

  • ✔️

    All components are custom-made to suit your wall layout, cradle height, fly drift, and structural requirements

Simple, strong, and low-maintenance — our guide systems are built to perform reliably for years to come.

Rope Locks

Rope locks are a critical safety feature in any counterweight system, designed to keep hauling lines securely in place when not in use.

Rope Locks
    Safety note:
  • 🎯

    Rope locks are typically set to slip at an out-of-balance load of 20–30kg – this helps prevent misuse as a primary load restraint, and reduces risk in runaway situations

A properly installed rope lock isn’t just convenient — it’s a key part of a safe, well-balanced fly system.

  • Here’s what we supply and install:
  • 🎯

    Heavy-duty rope locks – built for reliability and everyday use

  • 🔧

    Secure clamping mechanism – holds the hauling line firmly in place

  • ✔️

    Adjustable tension – allows fine-tuning to suit rope diameter and wear

  • ✔️

    Installed on the locking rail – for safe, easy access by operators

  • Other key features:
  • 🔧

    Compatible with manila, hempex, polypropylene, and hempflax hauling lines

  • ✔️

    Built for long-term use in high-traffic theatre environments

Lineset Boards

Lineset boards might be old-school, but they’re still one of the most useful tools in any fly tower. They give your crew a quick, at-a-glance reference for what each lineset is doing — whether it’s holding an LX bar, a curtain, scenery, or something else entirely.

  • Here’s what we typically supply:
  • 🎯

    Traditional chalkboard-style boards – still the go-to in most Aussie theatres

  • 🔧

    Easy to update – just wipe and re-label as your setup changes

  • ✔️

    Clear layout with lineset numbers and space to write notes for each line

  • Prefer something different?
  • 🎯

    We also offer whiteboard versions if you’d rather use markers than chalk

  • 🔧

    Digital displays are available too, if you’re after a more high-tech option

lineset boards

No matter the format, a well-laid-out lineset board helps keep everyone on the same page — especially during changeovers and cue-heavy shows.
We’ll make sure yours is tailored to your system and easy to use day in, day out.

Lift Lines & Terminations

Lift lines do the heavy lifting — literally. They’re what connect your battens to the cradles, running through pulleys to move everything up and down safely and smoothly.

lift lines

We custom-cut and prep every line to suit your system layout, so everything fits and functions exactly as it should. No guesswork — just solid, reliable rigging that’s built to last.

  • Here’s what we use:
  • 🎯

    5mm or 6mm steel wire rope, 6x19 fibre core or 7x19 steel core construction — tough, flexible, and perfect for theatre rigging

  • 🔧

    Machine-swaged terminations — done in-house for flexibility, providing a clean & permanent finish

  • ✔️

    Fitted with thimbles and ferrules to reduce wear and prevent slipping over time

    • And when it comes to safety, we build in plenty of headroom:
  • ✔️

    Our lift lines have a minimum safety factor of 8:1 — meaning each wire rope is rated to hold atleast eight times the working load

Hauling Lines

Hauling lines are what the operator pulls on — they’re the control point of the whole counterweight system. When you move a lineset up or down, you’re pulling the hauling line to do it.

A bit of history... Traditionally, manila rope was the go-to for hauling lines. Why? Because early theatres were often built and run by shipbuilders and riggers, who brought over materials and techniques straight from the docks. Manila, being strong, grippy, and familiar, became the standard.

These days... While manila still works, some venues now use synthetic alternatives that offer better durability and less maintenance. Synthetic is particularly preferred in venues that are exposed to rapid and varying temperatures as Manila stretches and contracts in humid / dry conditions.

  • We supply and install:
  • 🎯

    Manila – still available for traditionalists or heritage venues

  • 🔧

    Easy to update – just wipe and re-label as your setup changes

  • ✔️

    Clear layout with lineset numbers and space to write notes for each line

  • Prefer something different?
  • 🎯

    We also offer whiteboard versions if you’d rather use markers than chalk

  • 🔧

    Digital displays are available too, if you’re after a more high-tech option

No matter the format, a well-laid-out lineset board helps keep everyone on the same page — especially during changeovers and cue-heavy shows. We’ll make sure yours is tailored to your system and easy to use day in, day out.

Counterweights

Counterweights are what balance the load on your battens — whether it’s lights, curtains, scenery, or anything else flown in and out. They sit in the cradle and move opposite the batten to keep everything perfectly balanced and easy to operate.

Front Loading Weight

Side Loading Weight

  • We supply:
  • 🎯

    Traditional cast iron weights – designed for side-loading into standard top-loading cradles

  • 🔧

    Modern front-loading weights – shaped specifically to suit front-loading cradles, sliding in easily and locking safely into place

  • ✔️

    Storage solutions for easy storage on the mid and upper catwalks and at stage level

  • Standard sizes are:
  • 🎯

    6kg and 12kg blocks – the most common sizes used across most systems

  • 🔧

    Custom weights – available to suit specific system designs or space constraints

    • All weights are:

  • ✔️

    Cast for durability and long-term use

  • ✔️

    Easy to handle, stack, and secure in the cradle

  • ✔️

    Designed for a snug fit — no rattling, shifting, or misalignment during operation

Whether you're working with a traditional setup or a modern front-loading system, we’ll supply the right weights to keep your linesets balanced and your crew working safely and efficiently.

Battens

No two venues use the same battens — and that’s exactly how it should be. The right batten depends on what you're flying, how long it needs to be, and how you want to use it. We supply and install a full range of battens to suit all types of performance spaces, from simple setups to fully spec’d pro stages.

  • Here’s a quick rundown:
  • 🎯

    Standard 48OD pipe – your classic lighting batten, used just about everywhere

  • 🔧

    75x50 RHS battens – great for heavier scenic loads or when a bit of extra rigidity is needed

  • ✔️

    Flat truss battens – ideal when strength, cable management, or mounting flexibility is a priority

  • And then there are our in-house solutions:
  • 🎯

    ITE Multipurpose Truss Batten – strong, lightweight, and super versatile. These are especially popular for panorama bars, where you need to run trolleys for flexible lighting ladders or scenic movement

  • 🔧

    ITE LX Ultra Lighting Bar – purpose-built for modern lighting setups, with strength and clean cable management in mind

Need something unique? No problem — we can also custom-design battens to suit your space, load requirements, or rigging preferences. Whether you're flying lights, tabs, scenery, projection screens, or panorama ladders, we’ll match you with the right batten for the job.

Every batten we supply is:
• Designed for compatibility with your fly system
• Properly finished and labelled for easy identification
• Built to last and installed with safety, access, and usability in mind
Whether it’s simple pipe or a fully engineered truss solution, we’ve got you covered.

Rigging Irons

You can’t hang much without the bits that actually do the hanging. We supply all the rigging irons, barrel clamps, batten clamps and suspension backets you’ll need to connect battens, truss, lighting bars — or just about anything else — to your fly system.

  • Here’s what we typically provide:
  • 🎯

    Barrel / batten clamps – heavy-duty clamps designed to connect pipe securely to suspension points or rigging infrastructure

  • 🔧

    Lighting bar & truss suspension brackets – purpose-designed brackets that provide consistent support for LX bars & truss, preventing deflection and maintaining even trim height

All components are selected or custom-fabricated to suit your system’s configuration and load requirements, and are installed using appropriate high-tensile fasteners for maximum safety and reliability.

Safety Mesh Systems

Safety mesh systems are a relatively recent addition to modern counterweight installations — and they’re quickly becoming standard practice in many new venues.

  • Installed to the underside of the catwalks between the stage wall and the edge of the cradle run, these systems are designed to:
  • 🎯

    Contain falling counterweights or equipment in the rare event of a runaway cradle

  • 🔧

    Protect personnel and performers working or standing on stage from falling objects

At ITE, we custom design and install safety mesh systems to suit your space and structure. Built strong, installed cleanly, and engineered to give everyone on stage a bit more peace of mind.

safety mesh

Line Loks

Line Loks are a simple but incredibly useful addition to any fly system — giving you a quick and secure way to tie off spare hauling lines or set lines on stage.

  • Here’s what they do:
  • 🎯

    Securely hold rope under tension without the need for knots

  • 🔧

    Allow fast tie-offs for hauling lines, pick lines, or temporary rigging

  • ✔️

    Keep your ropework neat, safe, and out of the way

ITE Line Loks are compatible with most rope types used in counterweight systems — including manila, Hempex, and synthetic blends.
Strong, durable, and easy to use, Line Loks are one of those small details that make a big difference in everyday operation.

Frequently Asked Questions