In certain applications, non single-point failure systems are utilized.  In these systems there are redundancies for all critical components order to provide an additional margin of safety.

Flying harnesses

Flying harnesses worn by performers are considered a component of the rigging, and not a part of the costume.  Only qualified individuals shall perform construction, adaptation, and maintenance on flying harnesses.  Careful attention shall be paid so that any costume elements worn over flying harnesses do not impair the vision, mobility, and/or safety of the performers.

Our flying harnesses are primarily constructed of Type 7, Class 1, 1-3/4" wide nylon webbing that meets MIL-W-4088/27265 speculations. Some harnesses may contain 1" wide webbing.  All webbing in flying harnesses shall have a minimum tensile strength of 5,000 lbs.

All seams on harness straps (leg, shoulder, waist, and other critical components of the harness) shall have a minimum tensile strength of 2,000 lbs.

D-rings, harness plates, and swivel assemblies that are a part of a flying harness shall have a minimum tensile strength of 2,500 lbs.

Buckles on leg and shoulder straps of flying harnesses shall have a minimum tensile strength of 2,500 lbs., and buckles on waist belt shall have a minimum tensile strength of 500 lbs.

Flying harnesses shall not be dyed, painted or marked with any substance which could degrade the strength and/or integrity of the harness materials, or inhibit the free movement and/or flexibility of its parts.

Flying harnesses shall be inspected for wear or other defects by a competent person prior to each performance.

Flying Props

All flying props that support a performer shall have a minimum design factor of eight (8).

When there is risk of a performer falling from a flying prop, the performer shall be secured to the prop, by means of belts or harnesses.  Circus or gymnastic acts where the performer supports his/her own weight are exempt from this requirement.

Wire ropes

Selection of the size of wire ropes used for flying wire(s) shall be based upon the intended use, including the weight to be lifted, flying choreography (pendulums, somersaults, etc.), number of wire ropes supporting performer, rigging method, inspection schedule, and other relevant factors.

The efficiency rating of the wire rope termination method used shall be factored into the computed breaking strength of the wire rope, and selections of wire rope size shall be made by applying the design factor to the computed breaking strength.

In systems that use one or two flying wires, a minimum design factor of five (5) shall be used for each flying wire.

In systems that use three or more flying wires, where the performer's weight can be transferred to one or two wires, a minimum design factor of five (5) shall be used for each flying wire.

In systems that use three or more flying wires, where the performer's weight cannot be transferred to only one or two wires, the combined breaking strength of the minimum numbers of flying wires that can share the weight of the performer at one given time shall have a minimum design factor of five (5).

All working (lifting) cables shall have a minimum design factor of eight (8).

When rope, shock cord, fabric, or other specialty materials are used to support a performer, these components shall comply with the manufacturers' or vendors' specifications for their use.

Operating (lift) lines

Lift lines (ropes) shall have a minimum design factor of ten (10).

Pulleys, blocks, sheaves, and drums

The D:d ratio of a sheave (or drum) and the cable shall not be less than the minimum recommended by the wire rope manufacturer for the type of wire rope being used.

When pulleys, blocks, sheaves, or drums are used in a situation where the wire rope is subject to swing so that a fleet angle of the wire rope is greater than that recommend by the manufacturer, means to compensate for potential fleet angle problems and dynamic forces shall be incorporated.

Pulleys, blocks, and drums shall be designed in such a fashion as to prevent the wire rope from coming out of the groove and becoming jammed between the sheave and the side-plate of the pulley or block, or wrapping around the shaft of the drum.

The grooves in sheaves and drums shall be properly sized for the cable or rope being used.

The maximum load placed on any pulley, block, or drum shall not exceed the working load limit specified by the manufacturer.

Track and trolleys (carriers)

Rigid track and components used in flying effects shall have a minimum design factor of eight (8), and cable (wire rope) track shall have a minimum design factor of twelve (12).

Track sections shall be securely joined together by bolts to prevent sections of track from separating during use.

Track shall be supported according to manufacturer's recommendations.

Trolleys shall have a minimum design factor of eight (8).

Terminations and attachments

Swaging sleeves shall be fitted to manufacturer's specifications and compressions checked with a go/no go gauge in accordance with the manufacture's specification.

Swaging sleeves shall be made of copper, zinc-plated copper, or stainless steel, unless in conflict with a local, state, or national code.

All wire rope clips used for terminating wire ropes shall be forged, properly sized for the wire rope being used, and installed in accordance with the manufacturer's specifications. The use of malleable wire rope clips is not permitted.

All hardware or devices used to connect the flying wire to the harness shall have a minimum design factor of five (5).

All swivels, shackles, eye-bolts, rings, quick links, or other hardware that supports the performer's generated weight, excluding hardware for connecting the flying wire to the harnesses, shall have a minimum design factor of eight (8).

All rings shall be forged or welded to form a complete loop.

All eyebolts shall be forged to form a complete loop.  Open hooks or bent eyes shall not be used in any flying system.