Using Condors

Using a Condor / Boom Lift for Set Lighting Rigging

This article summarizes practical working knowledge from the CSATF B2 Boom Lift / Scissor Lift Rigging course book. It is not a substitute for the lift operator’s manual, the manufacturer’s supplemental rigging manual, employer rules, or current OSHA / Cal-OSHA requirements.

This PDF can be found here:

https://drive.google.com/file/d/1zWJnXjedpJtxdOAzH1QA4i5inzq-3LLs/view?usp=drive_link

Overview

A “Condor” is the common film-industry nickname for a boom lift. Boom lifts may also be called aerial devices, extensible boom platforms, stick booms, knuckle booms, cherry pickers, or Z-booms.

For set lighting work, a boom lift is often used to elevate both people and equipment. This makes it different from ordinary lift use. The operator and rigging crew must account for platform capacity, load position, wind resistance, cable management, reach limits, fall protection, electrical clearance, and whether the specific lift model is approved for the intended setup.

A Condor should not be treated as a tall rolling stand. It is a mobile elevating work platform with strict manufacturer limits.

The Industry Exception

In normal aerial lift use, equipment is generally not supposed to be attached to the guardrails or extended outside the platform. The motion picture industry has a limited exception from certain manufacturers that allows trained and authorized set lighting technicians and grips to attach approved lighting, camera, and grip equipment to certain boom lift platforms.

This exception is limited. It applies only when:

• The worker is trained and authorized.
• The exact lift model is covered by the manufacturer’s supplemental manual.
• The setup follows the supplemental manual.
• Load capacity is correctly reduced when required.
• Wind limits are followed.
• Electrical approach distances are followed.
• The lift is used within all manufacturer and employer restrictions.

Genie, JLG, and Snorkel each have their own supplemental information. The exact approved models, calculations, and restrictions must be checked in the current manual for the exact lift being used.

Do not assume that because one boom lift is approved, another similar-looking boom lift is also approved.

Boom Lifts vs. Scissor Lifts

Boom lifts and scissor lifts are treated differently.

The production rigging exception applies to specific boom lift models only. Scissor lifts are not covered by the same exception. For scissor lifts, follow the normal operator’s manual unless there is written manufacturer permission for a specific use.

In practical terms:

• A boom lift may be approved for certain production rigging if the manufacturer’s supplemental manual allows it.
• A scissor lift should generally be treated as an elevated work platform, not as a rigging structure.
• Camera, lighting, or grip equipment used on a scissor lift should fit inside the platform unless written manufacturer approval says otherwise.
• Do not attach equipment to a scissor lift guardrail or extend equipment outside the platform without specific written permission.

Choosing the Right Lift

Before rigging from a Condor, confirm that the lift is appropriate for the job.

Important questions include:

• Is the exact model approved for film-production rigging?
• Does the lift have enough height and reach?
• Does the lift have enough platform capacity after adjusted-weight calculations?
• Will the platform need to operate in a restricted-capacity zone?
• Will the equipment create too much wind resistance?
• Will the lift be working on firm, level, appropriate ground?
• Is there enough room for boom swing, backswing, cable movement, and safe travel?
• Are there power lines or electrical hazards nearby?
• Will the rig block controls, gates, decals, manuals, anchor points, or operator movement?

The lift should be selected for the full setup, not just for height. A smaller lift may technically reach the work area but still be unsuitable because of capacity, reach envelope, slope, wind exposure, or cable management.

Platform Capacity

Every boom lift has a rated platform capacity. This is the maximum load allowed in the platform under specified conditions. Some lifts have different capacity zones, such as unrestricted and restricted capacity.

A common example is a lift that allows a lower weight throughout the full working envelope, but allows a higher weight only in a smaller range of boom positions.

Always check:

• The lift decals
• The operator’s manual
• The manufacturer’s capacity chart
• The supplemental rigging manual, if equipment is attached to the platform or guardrails

Never use the maximum platform capacity as a rough guess. The usable capacity may change based on boom position, load location, and whether the equipment extends outside the basket.

Direct Weight and Adjusted Weight

When rigging from a Condor, not all weight counts the same way.

Direct Weight

Direct weight is weight carried in the platform in the normal way. This includes:

• Operators
• Occupants
• Tools
• Equipment inside the basket
• Items whose center of gravity remains within the normal platform area

Personnel weight is always direct weight.

Adjusted Weight

Adjusted weight applies when equipment is attached to the guardrail or extends outside the platform. The farther the equipment sits outside the basket, the more leverage it creates. Because of this leverage, the equipment may count as much more than its actual scale weight.

For example, a 100 lb fixture rigged far outside the platform may count as much more than 100 lb against the platform capacity. The exact adjusted value must be taken from the manufacturer’s chart.

The basic concept is:

• Weight inside the platform usually counts as direct weight.
• Weight attached outside the platform must usually be adjusted.
• The farther out the load is, the more capacity it consumes.
• The adjusted-weight chart, not a guess, determines the value.

Basic Capacity Calculation Workflow

A practical capacity workflow is:

1. Confirm that the lift model is approved for the intended rigging use.
2. Find the correct manufacturer supplemental manual for that model and serial range.
3. Determine the actual weight of each item.
4. Separate direct weight from outside or offset weight.
5. Measure the distance from the manufacturer’s required reference point to the load’s center of gravity.
6. Round up where the chart requires it.
7. Use the supplemental manual’s adjusted-weight chart.
8. Add direct weight and adjusted weight.
9. Compare the total against the lift’s rated capacity.
10. Confirm that the intended boom position is allowed on the lift’s reach and capacity chart.

Items to include in the calculation may include:

• Fixture
• Yoke
• Pipe
• Clamps
• Diffusion frame
• Cable supported by the basket or boom
• Accessories
• Operator and occupants
• Tools and personal equipment

The practical rule is: if it is on, in, attached to, or supported by the platform, it has to be accounted for.

Please see the booklet for exact methods for calculation.

Wind and Surface Area

Wind is one of the most important issues when rigging lighting equipment from a Condor. A setup may be acceptable by weight but unacceptable because of wind resistance.

Large flat or broad items can act like sails, including:

• Diffusion frames
• Rags
• Solids
• Flags
• Bounce materials
• Large LED panels
• Soft boxes
• Multiple fixtures on pipe

Here is the summarized workflow, but again refer to the PDF to determine this.

1. Calculate the load weight.
2. Determine the exposed surface area.
3. Check the manufacturer’s wind-speed chart.
4. Follow the most restrictive applicable limit.

The manufacturer may require a lower maximum wind speed when equipment has more surface area. Employer rules or production safety rules may also be stricter.

If the setup involves large diffusion, large soft sources, or wind exposure, use the actual book and manufacturer manual. This is not a situation where field judgment should replace the chart.

Attaching Equipment to the Basket

Equipment attached to the basket must not damage the lift or interfere with safe operation.

Do not:

• Attach equipment to fall-protection anchor points.
• Drill, weld, or modify the platform.
• Overtighten clamps enough to dent or damage guardrails.
• Block the entry gate.
• Block the footswitch.
• Block the control panel.
• Block fall-protection anchor points.
• Block safety decals.
• Block the manual holder.
• Place fixture switches or controls out of safe reach.

Equipment controls should not be raised higher than the tallest occupant can safely reach from the platform floor. Do not stand on the guardrail, toe board, apple boxes, cases, or other objects to reach equipment.

Use safety cables where appropriate to prevent equipment from falling from the platform.

Cable Management

Cable management is a major part of safe Condor work. Poorly managed cable can snag, pull the basket, create side load, get run over, become unplugged, or damage equipment.

A clean cable setup should:

• Keep cable out of the lift’s power track.
• Avoid pinching, stretching, cutting, or snagging.
• Leave enough slack for boom movement.
• Avoid creating side load or vertical load on the platform. This means cable should be secured to the arm and not allowed to drape straight down.
• Keep unused cable neatly coiled and tied off inside the basket.
• Keep cable away from the operator’s feet and controls.
• Keep ground cable routed so the lift cannot drive over it.
• Be tested by extending and retracting the boom before equipment is powered.

For powered equipment on a boom lift, cable may need to be secured along the boom using approved rollers or other allowed methods. If rollers are used, they should be attached without drilling, welding, or permanently modifying the lift. Strap ends and loose cable must be kept away from moving parts.

Before energizing equipment, move the boom through the expected range of motion and confirm that the cable travels freely.

Driving and Moving the Lift

Lifts should generally be driven with the platform in the lowest recommended driving position.

Driving while elevated is allowed only under limited conditions, such as:

• The surface is firm, smooth, and level.
• The surface is free of holes, debris, bumps, edges, or unstable areas.
• The operator has a clear view of the travel path.
• The lift is operated at the manufacturer’s allowed speed.
• The employer allows elevated travel.

Some employers may prohibit driving while elevated even if the manufacturer allows it.

With equipment rigged to the platform, be more conservative. The rig may change the center of gravity, increase wind exposure, and complicate cable movement. In many cases, lowering the platform before repositioning is the better choice.

Stability and Center of Gravity

A boom lift remains stable only while its combined center of gravity stays within the machine’s stability area. Raising the platform, extending the boom, driving on a grade, adding load, or attaching equipment outside the basket can all shift the center of gravity.

Common causes of instability include:

• Overloading the platform
• Rigging equipment too far outside the basket
• Working in high wind
• Driving while elevated
• Side loading
• Working on too steep a slope
• Driving over curbs, bumps, holes, or unstable surfaces
• Using the lift as a crane

A Condor should never be used to hoist or crane a load.

Working on a Grade and Cribbing

Boom lifts and scissor lifts are designed to operate on level surfaces. Some boom lifts may be driven over low inclines under limited conditions, but the manufacturer’s gradeability and side-slope ratings must be followed.

Do not:

• Drive on an incline while elevated.
• Turn on an incline.
• Assume that a lift can work safely just because it can drive onto the surface.

If a lift must work on a slope, the machine itself must be made level using manufacturer-approved methods.

Some Genie and JLG boom lifts may be approved for wood cribbing under specific conditions. Snorkel does not allow its lifts to be leveled with cribbing blocks. Cribbing is not approved for scissor lifts.

Cribbing restrictions include:

• Use cribbing only on a firm surface that can support the lift, load, and cribbing.
• Do not use cribbing over a hole or bump.
• Inspect cribbing before use.
• Drive onto cribbing slowly with the platform lowered.
• Do not turn on cribbing.
• Do not crib only one tire.
• Support the required two tires according to the approved cribbing method.
• Use only machines with the required lockout switch.
• Engage the lockout before raising the platform.
• Follow all wind restrictions.

A lift model may be approved for cribbing but not rigging, or approved for rigging but not cribbing. Check the specific manual.

Power Lines and Electrical Clearance

Minimum safe approach distance must be maintained around energized power lines.

In California, if a line is between 600 and 50,000 volts, all parts of the lift must remain at least 10 feet away. Higher voltages require greater clearance. Employer rules may be stricter.

If the voltage is unknown:

• Assume the line is energized.
• Stay away.
• Identify the pole number if possible.
• Contact the utility company or request a pole spotter.
• Follow the applicable safety bulletin, employer policy, and local regulation.

This is a situation where the book, employer safety department, and applicable regulations should be consulted directly.

Pre-Use Inspection

A pre-use inspection should be performed at the beginning of each workday or shift.

Work Zone Inspection

Check the area where the lift will operate.

Look for:

• Ground conditions
• Side obstructions
• Overhead obstructions
• Non-load-bearing surfaces
• Concealed holes or pits
• Stage or location floor weight limits
• Electrical hazards
• Traffic or pedestrian conflicts
• Weather exposure
• Cable path issues

A properly rigged lift can still be unsafe if the ground, floor, or travel path is wrong.

Walk-Around Inspection

Check the physical condition of the lift.

Look for:

• Leaks
• Cracked hoses
• Damaged guardrails
• Missing decals
• Missing manuals
• Loose or damaged parts
• Unauthorized modifications
• Tire or wheel issues
• General damage or poor maintenance

Do not use a lift that is damaged, modified, missing required information, or visibly defective.

Function Test

Test the lift’s operation before use.

Check:

• Ground controls
• Platform controls
• Emergency stop
• Boom extension and retraction
• Platform raise and lower
• Drive function
• Brake function
• Steering
• Alarms or warning systems

If any part of the lift fails inspection or function testing, take it out of service and notify the appropriate supervisor or safety representative.

Fall Protection

All occupants in a boom lift platform must wear a full-body harness with an appropriate fall restraint or fall arrest lanyard connected to an authorized anchor point.

Important points:

• Use only approved anchor points.
• Attach only one harness per anchor point unless the manufacturer allows otherwise.
• Do not use body belts for fall protection.
• Do not attach equipment, cable, or rigging to fall-protection anchor points.
• Keep the lanyard short enough and appropriate for the work.
• If the platform has no dedicated fall-protection anchor points, ask the employer or safety representative how to proceed.

Scissor lift occupants may not always be required to wear fall protection unless specified by employer policy, local regulation, or site rules. Follow the stricter requirement.

Common Condor Rigging Mistakes

Common problems include:

• Using a lift model that is not approved for production rigging.
• Using the wrong supplemental manual.
• Calculating actual weight but not adjusted weight.
• Ignoring the effect of load distance from the basket.
• Forgetting to include pipe, clamps, cable, yokes, or accessories in the load calculation.
• Passing the weight limit but failing the wind/surface-area limit.
• Blocking the gate, footswitch, controls, decals, manual holder, or anchor points.
• Attaching gear to fall-protection anchor points.
• Damaging guardrails with overtightened clamps.
• Letting cable create side load.
• Letting cable snag, pinch, stretch, or get driven over.
• Driving while elevated without meeting the required conditions.
• Using cribbing on an unapproved model.
• Treating a scissor lift like it has the same rigging exception as a boom lift.
• Working too close to power lines.
• Using the lift as a crane.

When to Check the Book or Manufacturer Manual

Use the actual course book and manufacturer manual whenever the setup involves:

• Equipment attached outside the platform
• Guardrail-mounted equipment
• Adjusted-weight calculations
• Large diffusion or large soft sources
• Wind exposure
• Capacity or reach-chart questions
• Cribbing
• Work on a grade
• Work near power lines
• Scissor lift side-force limits
• Unusual cable routing
• Any lift model or serial number uncertainty

The field concept is straightforward: use an approved lift, use the correct manual, calculate the load correctly, check wind, attach equipment without interfering with the platform, and manage cable so it cannot pull, snag, or create side load.

The exact numbers must come from the applicable manufacturer charts.