Truss Operating Manual

Version 7a

Total Solutions Group, Kingston Industrial Estate, 81 - 86 Glover Street, Birmingham, B9 4EN, England
T. +44 (0)121 772 5234 E. sales@trussing.com
www.trussing.com
1 Operating Manual for Modular Aluminium Truss
Sections designed and manufactured by Total Solutions
Group
1.1 This document provides the guidelines and recommendations for the
use, handling, care and future inspection of the truss for the benefit of the
user. Some general matters of safety are also discussed, but these
should not be considered as an exhaustive list and users shall satisfy
themselves that all reasonable steps are taken to ensure the safety of the
personnel who are erecting and dismantling the system.
1.2 Trusses are normally made from aluminium to be light weight, easily
movable, and generally to have an easy and quick method of fixing

2 Version
Version: 7
Date: 10th December 2018
2.1 Other operating Manuals
2.1.1 The User shall also read the “Operating Manual for Demountable
Aluminium Roof Top Structures” where appropriate. This
document is available from Total Solutions Group. Sections of
that Operating Manual are similar to sections in this Manual,
however they should be read in conjunction with each other.
2.1.2 The User shall read and fully understand both this manual and all
other relevant Operating Manuals which are available from TSG
before attempting set up a structure without a consultant from
TSG being present.
2.1.3 If Users are unclear about any aspect of the operation, then they
shall seek advice from TSG before proceeding.

3 Important
3.1 Read Carefully Before Use
3.2 Keep for Future Reference
3.3 This manual is applicable to all TSG Truss ranges.
3.4 See section 24 Product Specific information for user information regarding
specific product types

Page 1 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 3.5 Danger: For intended use only.
3.6 Danger: Do not apply other manufacturers’ instructions to TSG products.
3.7 Danger: Do not climb Truss
3.8 Danger: Do not modify Truss
3.9 Danger: Holes should never be drilled in a truss.
3.10 Warning: Aluminium and steel conduct electricity
3.11 Warning: All load tables assume loading on the bottom cords
3.12 Warning: Do not use in a severe marine environment
3.13 Warning: Do not store in freezing conditions
3.14 Warning: This product shall only be used by a competent person.
3.15 Warning: This product shall not be used by children
3.16 Warning: Always inspect product prior to use.
3.17 Warning: Appropriate PPE should be used where necessary
3.18 Warning; Wear hearing protection when hammering pins
3.19 Warning: Never undertake repairs or welding to trusses.
3.20 Caution: Do not consume.
3.21 Any of the above items can lead to the following consequences.
• Invalidation of warranty

• refusal of support services

• structural failure

• damage to property

• injury or death

4 Users
• This product is to be used only by competent persons.

• This product shall not be used by children

Page 2 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

5 Contents

1 Operating Manual for Modular Aluminium Truss Sections designed and

manufactured by Total Solutions Group ......................................................... - 1 -

2 Version ..................................................................................................... - 1 -

3 Important ................................................................................................. - 1 -

4 Users........................................................................................................ - 2 -

5 Contents .................................................................................................. - 3 -

6 Terms and Definitions ............................................................................. - 4 -

7 Principles of Design................................................................................. - 7 -

8 General Notes.......................................................................................... - 8 -

9 Tools and Equipment ............................................................................ - 10 -

10 Assembly and connection of trusses .................................................... - 10 -

11 Discontinuity of bracing (‘Mis-noding’) ................................................. - 12 -

12 Loading .................................................................................................. - 12 -

13 Lifting Trusses with hoists or winches ................................................... - 15 -

14 Trusses and People............................................................................... - 16 -

15 Cantilever trusses .................................................................................. - 17 -

16 Curved and Circular trusses.................................................................. - 17 -

17 Identification and Serial Numbers ......................................................... - 18 -

18 Wind loads ............................................................................................. - 19 -

19 Earthing (Equipotential bonding) .......................................................... - 19 -

20 Inspection and Maintenance ................................................................. - 19 -

21 Transportation, handling and storage ................................................... - 22 -

22 Spares and Replacement parts ............................................................ - 23 -

23 Disposal and Recycling......................................................................... - 23 -

Page 3 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 24 Product Specific information ................................................................. - 23 -

25 List of Significant Hazards ..................................................................... - 23 -

26 References............................................................................................. - 25 -

27 Inspection and Maintenance record ..................................................... - 25 -

6 Terms and Definitions

Associated structural components
Corner modules, sleeve modules or any accessories designed to be
connected to trusses.
Centre Point Load (CPL)
A single load applied at the center of a simple span.
Competent Person
A person who has the necessary knowledge, skill and experience to carry out
the task at hand.
Connection
Connectors or connection elements needed to connect modules and
associated structural components.
Connection element
Loose parts for assembling truss modules and associated structural
components.
Connector
Permanently fixed connection components of truss modules and associated
structural components.
Dead load
The self-weight of the modules.
Dynamic load
A structurally significant magnification of design load due to movement.
End Point Load (EPL)
Single load applied at the unsupported end of a cantilever.

Page 4 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 Frequent use factor
Reduction factor used when calculating allowable loads.
Hoist Class
Guidance for crane classification for fatigue, as defined in BS EN 1991-3:2006
Annex B.
Imposed Load
The load imposed by fixtures (including cabling) or other equipment carried by
or attached to a truss.
Main chord
Longitudinal member of a truss module.
Module
Lattice structure intended to be used on its own or in combination with other
modules.
Monotonic
For which the variation is always in the same direction.
Permanent Action
Action that is likely to act throughout a given reference period and for which
the variation in magnitude with time is negligible, or for which the variation is
always in the same direction (monotonic) until the action attains a certain limit
value.
Quarter Point load (QPL)
Three single loads applied to a simple span that divides the span into
quarters.
Side adapters
Connection elements that allow the connection of a module to the face of
another module without using a corner block.
Simple Span
The distance between the supports in a horizontal truss.
Snug-tight
‘A condition achievable by the effort of one person using a spanner without an
extension arm’ for tightening bolts.

Page 5 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 TFL
Total Fabrications Ltd (part of the Total Solutions Group).
Third Point load (TPL)
Two single loads applied to a simple span that divides the span into thirds.
Tower system
Combination of truss-modules and associated structural components,
intended to move and hold truss-modules and other loads.
Truss
A series of modules connected together.
TSG
Total Solutions Group.
Uniformly Distributed Load (UDL)
A load evenly applied across a simple span.
Variable Action
Action for which the variation in magnitude with time is neither negligible nor
monotonic.

Page 6 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

7 Principles of Design
Load
7.1 Dependant on its orientation, loading pattern and spacing and number of
supports the chords of a truss are in either tension or compression to
develop an internal torque or bending moment. The bottom chord is in
tension, and the top chord in compression.
7.2 The diagonal and vertical members carry the shear force. Individually,
they are also in tension and compression, the exact arrangement of
forces is depending on the type of truss and again on the direction of
bending. In the truss shown above right, the vertical members are in
tension, and the diagonals are in compression. Fig. 1
7.3 Trusses must always be used in accordance with the manufacturers’ Tension
instructions.
7.4 There should be diagonal braces in the same plane as the load being
applied to the truss. For a vertical load, the bracing must be in the sides
of the truss. If the load was applied to the truss horizontally, the diagonal Support Support
bracing in the top and bottom faces of the truss. Fig. 2 Fig. 1 – Forces (7.2)
7.5 There are trusses made with bracing on three sides. In using these
trusses, care must be taken to ensure that for a vertical load, two of the
braced faces are in the vertical plane. Fig. 3
7.6 The truss is designed to transfer load through the connections, so all the
connections must be properly made using the components that were
designed to do the job. Pins or bolts must never be left out, improvised or
substituted. Damage to the ends of chords, connecting plates, or holes in
spigots or fork end connectors will prevent the connection from working
efficiently and inhibit the load carrying capacity of the truss.
7.7 Trusses are generally connected in one of three ways. Sections are
bolted together using bolts in tension through plate connections, Fig. 4,
Load
or the chords are connected by spigot or fork end connections with shear
pins, Fig. 5, Fig. 6. The connections are of vital importance since they
must be as strong as the trusses and transfer loads efficiently.
7.8 Important: Never connect trusses from different manufactures.
7.9 Important: Never create a span using modules from different product
ranges.
7.10 The members in a truss have a specific function. Damaging one member
can significantly affect the strength of the whole truss.
Fig. 2 - Vertical and Side loading brace arrangements (7.4)

Page 7 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 7.11 Trusses are designed to carry loads at the node points (the points at
which members meet). The truss derives its strength from the chords
and bracing members being either stretched in tension or squashed
axially in compression. Any force that causes a member to deviate from
its long axis (centreline) may weaken the overall structure.
7.12 Cantilevers can create forces in a truss that may weaken it and guidance
should be sought TSG. Loading tables to EN 17115 specify available
cantilever load for a given distance.
7.13 Application of loads between the node points may lead to local bending
of the members which could lead to damage to or failure of the truss. Fig.
7
7.14 Loading tables to EN 17115 specify allowable loads between node points
on a chord but such loads should only be applied after consulting the
relevant structural documentation, Fig. 8 Fig. 3 - Truss with diagonals on three faces (7.5)

8 General Notes
8.1 The trusses are designed to be used under normal operating conditions
and not in extremes of temperature or other particularly adverse
conditions.
8.2 Important: The use of lifting equipment is outside of the scope of this
manual. The user should seek advice from the manufacturer as required.
8.3 Materials
8.3.1 The material generally used in the manufacture of the truss is
6082 - T6 aluminium alloy.
Fig. 4 – Bolt (7.7) Fig. 5 – Pin (7.7) Fig. 6 - Taper Pin (7.7)
8.3.2 Surface protection is only needed where the truss is used in
severe urban, industrial or marine environments.
8.4 Certification, testing and inspection
8.4.1 Persons supplying work equipment are responsible for ensuring
that the truss modules are inspected at the appropriate frequency.
8.4.2 The inspection schedule is dependent on such things as
frequency of use, typical and maximum imposed loads and this is
discussed later. See Inspection and Maintenance
8.4.3 Modules must be visually checked by the user for damage before
and during assembly.
8.4.4 Modules shall not be used if damaged beyond TSG guidelines. Load
See Inspection and Maintenance Fig. 7 – Loads (7.13)

Page 8 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 8.5 Load Tables, Fig. 9
8.5.1 Caution: Trusses should be used only in accordance with the load
tables relating to that truss type.
8.5.2 Differences in wall thickness, bracing angles, connections and
other factors will significantly alter the performance of a truss.
8.5.3 Warning: Using trusses as towers, applying loads other than in the
vertical plane and in cantilever can also change the allowable
loads shown in tables.
8.5.4 Always consult TSG if the desired application is not explicitly
shown in the load tables or other documentation.
8.6 Span
8.6.1 Span between supports is the critical factor in using trusses. The
greater the span, the weaker the truss. This is due to both the Fig. 9 - Typical Load Table (8.5)
stiffness of the truss in the vertical plane and in the horizontal
plane, Fig. 8
Span
8.6.2 If a truss is subject to twisting or lateral movement its capacity to
carry loads is affected, Fig. 10
8.6.3 Always stay within the quoted spans in load tables.
8.6.4 Load conditions: uniformly distributed loads [UDL], central point
load [CPL], third point load [TPL] and quarter point load [QPL]. – Fig. 8 - Span between supports (8.6.1)
Fig. 16, Fig. 17, Fig. 18 and Fig. 19
Load
8.6.5 Multiple pickups/supports require the loads to be calculated by a
qualified person with reference to the structural report for the truss
in question, Fig. 11
8.6.6 Caution: It should be noted that levelling a truss is no guarantee
that the loads are shared evenly between supports.
8.6.7 The only way of accurately monitoring loads on trusses with
multiple supports is to use a load cell on each support. Load
8.7 Supervision of erection, rigging and dismantling of the Structure
Fig. 10 – Twisting (8.6.2)
8.7.1 Warning: The erection, any modification and the subsequent
dismantling of the structure shall be planned and supervised by a P1 P2 P3 P4
competent person
8.7.2 Warning: A competent person shall be responsible for the safe
erection or rigging of the structure and check that all components
and fasteners are in place and functioning satisfactorily.
Fig. 11 - Multiple Supports (8.6.5)

Page 9 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 8.7.3 Warning: The structure must be checked for damage during and
on completion of the erection or dismantling of the structure.
8.8 Existing Structures
8.8.1 Warning: It is the responsibility of the user to check that the
existing structures which support the trusses, towers and / or grid
are adequate for the purpose.

9 Tools and Equipment

9.1 Pinned connections require
9.1.1 Hammers – ‘soft’ hammers preferred provided they have weight
9.1.2 Drifts / prybars / podgers
9.2 Bolted connections require
9.2.1 Ratchet sets – extended sockets are useful
9.2.2 Warning: Do not extend spanner handles
9.2.3 Ring spanners
9.2.4 Drifts / prybars / podgers
9.3 Additional equipment a user may find useful to provide when assembling
modules to form structures could include
9.3.1 baulks of timber,
9.3.2 pallet trucks and
9.3.3 small bottle or scissor jacks to support modules level,
9.3.4 ratchet straps to pull together modules to be connected,
9.3.5 short lengths of tube to act as rollers,
9.3.6 laser levels and plumb bobs.

10 Assembly and connection of trusses

10.1 Nut and Bolt Fixings. Fig. 12
10.1.1 All bolts, or other connectors, shall be the size, type and grade
shown on the relevant data sheet.
10.1.2 All bolts shall be used with the appropriate washers and nuts.
10.1.3 Use a drift or podger to line up the holes

Page 10 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 10.1.4 Nuts only need to be tightened such that the connection is
brought to a ‘snug-tight’ condition. (See definitions)
10.1.5 Warning: Do not over-tighten bolts.
10.1.6 Important: No torque is required for the strength of the connection
10.1.7 Warning: Do not use bolts to pull together parts of the structure.
Load straps may be used instead. These should be attached at
node points on a module.
10.1.8 Important: Do not use damaged and / or corroded bolts.
10.2 Fork-end or Spigot fixings. Fig. 13
10.2.1 Offer the connection up and where possible, use a drift or podger Fig. 12 - Nut & Bolt Fixings (10.1)
to gently line up the holes.
Insert R Clip Insert remaining
10.2.2 Fit one pin and use the podger to line up the opposite hole whilst R Clips
fitting the other pins.
10.2.3 It is often better to fit pins with the head inside the truss, making it
easier to drive the pins out when dismantling the structure.
10.2.4 Caution: Using a hammer inside the truss is inefficient and may
cause injury.
10.2.5 Use a long-tapered drift to drive pins out, or a pin puller.
10.2.6 Caution: Take care to strike the pin and not the connector or truss
material.
10.2.7 Warning: Only use the R clips supplied.
10.2.8 Warning: PVC tape is not an appropriate substitute for R clips
which prevent the pin from being drawn into the connection under Fig. 13 – Fork-end or Spigot Fixings (10.2)
load.
10.3 Taper or Conical pin fixings. Fig. 14
10.3.1 Important: The pin will only fit from one side.
10.3.2 When one pin is fitted, install the correct R clip to prevent the pin
from falling out when the others are being fitted.
10.3.3 Caution: Take care to strike the pin and not the connector or truss
material.
10.3.4 Warning: Only use the R clips supplied.
10.3.5 Warning: PVC tape is not an appropriate substitute for R clips
which prevent the pin from being drawn into the connection under
load. Fig. 14 - Taper or Conical Fixings (10.3)

Page 11 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 10.4 On heavier trusses, damage is often caused by poor handling and
storage, forcing connections (hammering and bending members by
levering, pulling sections together with load straps attached to them and
so on), overtightening fixtures and fittings, and over spanning during
assembly.

11 Discontinuity of bracing (‘Mis-noding’)

11.1 Mis-noding of truss can occur when two trusses are joined together, and
the continuous bracing pattern is interrupted so the proper transfer of
loads through the truss can no longer occur. Fig. 15
11.2 Warning; Mis-noding can lead to severe structural consequences and
possible collapse of the structure.
11.3 Important: Truss designs differ and may be susceptible to mis-noding
during construction.
11.4 Caution: Check data sheet to ensure truss is oriented correctly.
11.5 Consult TSG for instructions if you are unsure of how to connect modules
or connection elements.

12 Loading
12.1 Load Tables
12.1.1 Caution: Trusses should be used only in accordance with the load
tables relating to that specific truss type.
12.1.2 Warning; Load table data is for vertical imposed loads only. See
Fig. 9 Fig. 15 - Mis-noding or not mis-noding (11.1)

12.1.3 Warning: All load tables assume loading on the bottom cords. For
other loading scenarios seek advice from a competent person.
12.1.4 Warning: Using trusses as towers, applying loads other than in the
vertical plane and in a cantilever, will change the allowable loads
shown in tables.
12.1.5 Load tables provide the allowable Imposed Load for a given
simple span.
12.1.6 Always consult TSG if the desired application is not explicitly
shown in the load tables or other documentation.
12.2 Span

Page 12 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 12.2.1 Span between supports is the critical factor in using trusses. The
greater the span, the weaker the truss.
12.2.2 Always stay within the quoted spans in load tables.
12.2.3 If a truss is subject to twisting or lateral movement its capacity for
imposed loads is affected.by the following conditions: uniformly
distributed loads [UDL], central point load [CPL], third point load
[TPL] and quarter point load [QPL]. Fig. 16, Fig. 17, Fig. 18 and
Fig. 19 Fig. 16 - Uniform Loading (12.2.3)
12.2.4 Caution; Multiple pickups/supports require the loads to be
calculated by a qualified person.
12.2.5 Caution: It should be noted that levelling a truss is no guarantee
that the loads are shared evenly between supports.
12.2.6 The only way of accurately monitoring loads on trusses with
multiple supports is to use a load cell on each support.
12.3 Imposed Loads = =
12.3.1 Warning: On no account should a truss be used where the Fig. 17 - Centre Point Loading (12.2.3)
allowable load for the intended span has not been defined in the
relevant TSG load table.
12.3.2 Caution: There are numerous configurations to which the truss
could be subjected, and it is not possible to cover every case in
the structural calculations.
12.3.3 Warning: Application of loads between the node points may
lead to local bending of the members and so should only be
applied after consulting the relevant TSG load tables. Fig. 7 = = =
12.3.4 Loading tables to EN 17115 specify maximum imposed loading Fig. 18 - Third Point Loading (12.2.3)
on main members between two node points. Fig. 9
12.3.5 It is recommended that the user seeks advice from a competent
person when considering a truss to be moved during a show or
when dynamic loads are to be applied.
12.3.6 Dynamic load is transferred throughout the entire load path from
the imposed load and into the supporting structure. Fig. 20
12.3.7 No torsion or undue twisting shall be induced in the truss. Fig. 21
12.3.8 Distribute Imposed Load across the width of the truss to keep
= = = =
the sides level and vertical, Fig. 22. The load tables have been Fig. 19 - Quarter Point Loading (12.2.3)
produced assuming that the payload comprises vertical loads
only.

Page 13 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 12.3.9 Caution: It should be noted that electrical cable drops can impose
a considerable force on the structure particularly if the cables are
grouped together.
12.4 Side Adapters
12.4.1 The Imposed Load of the truss which supports the primary truss
shall be limited to a factor of 0.43 in the relevant load tables. Fig.
23
12.5 Self-weight
Load
12.5.1 TSG load tables take into account the self-weight of the truss
modules in a simple span. Fig. 21 – No Torsion (12.3.7)
12.5.2 Caution: TSG Load tables do not include the self-weight of any
secondary trusses which may be required to support additional
loads. Fig. 24
12.5.3 Allowable Imposed Load on a TSG truss is defined in the load
tables
12.5.4 The span of truss is established as being the distance between
the support points and the allowable load is read from the graphs.
Fig. 20 - Dynamic Load Path (12.3.6)
12.5.5 Important: For complex load scenarios advice should be sought Load
from a competent person who has adequate experience in the
use of structures of this type and they are in any doubt or
uncertain about the analysis of an arrangement of loading and the Fig. 22 - Load evenly
(12.3.8)
consequent effects on the truss.
12.5.6 If a truss is to be lifted, then account shall be taken by the user of
the dynamic loads associated with the speed of lift.
12.5.7 Caution: An appropriate dynamic magnification factor to reduce
the allowable static Imposed Load shall be defined by the user.
12.6 Frequent Use Factor
12.6.1 If the trusses are to be reconfigured repeatedly, it is best practice
to reduce the allowable loads to allow for minor damage to the
modules
12.6.2 This reduction factor by which the theoretical loads are normally
multiplied is 0.85.
12.6.3 This reduction factor has been used in all TSG structural reports to
British Standards and Eurocode
12.6.4 Slick reports to German standards (DIN) do not have this factor Fig. 23 - 0.43 x Truss Load (12.4.1)
applied.

Page 14 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 12.6.5 Important: If users are in doubt about whether the reduction
factor has been used, then they shall contact TSG and seek
advice Secondary Truss

13 Lifting Trusses with hoists or winches

13.1 Lifting with hoists or winches should only be planned and carried out by a
competent person(s)
13.2 If a truss is lifted using chain hoists or similar, then account shall be taken
by the user of the “snatch” loads associated with lifting. A dynamic
magnification factor shall be used to reduce the allowable static Imposed Fig. 24 - Secondary truss self-weight (12.5.2)
Load. The value of this dynamic magnification factor shall be defined by
the user.
13.3 Warning; load table information does not make any allowance for
dynamic forces.
13.4 Warning; Always know the load to be lifted. It is essential to know the
value of any imposed loads and how the truss itself is supported.
13.5 Dead load
13.5.1 TSG load tables make an allowance for the self-weight of the truss
in a simple span.
13.6 Dynamic loads
13.6.1 Starting or stopping at a speed of 4m per minute produces a Fig. 25 - Single Span (13.7.3)
‘snatch’ effect roughly equivalent to a 25% increase in load on the
lifting equipment and the supporting structure.
13.6.2 Faster lifting speeds further magnifies the dynamic effect.
13.7 Suspension of trusses; ‘rigging’
13.7.1 Only to be planned and carried out by a competent person(s)
13.7.2 Connection elements used to connect lifting equipment to trusses
should be of sufficient capacity to support the calculated load.
Load

13.7.3 On a single truss span suspensions must be fitted to the top

chords to prevent overturning. Fig. 25
13.7.4 Suspensions should generally be located at node points. Fig. 26 Fig. 26 - Node Point locations
(13.7.4) Load
13.7.5 For suspension use a TSG purpose designed ‘pick-up beam’ or a
round sling or softened wire rope as determined by a competent
person.

Page 15 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 13.7.6 Do not use two connection elements on the same chords in the
same bay. Fig. 27
13.7.7 Connection elements can be fitted to upper or lower chords.
13.7.8 Avoid letting slack motors sit on pick up beams, Fig. 28, they can
cause twisting of the pickup beam and damage the hoist should it
slip off.
13.7.9 Ensure the suspension applies load to the pick-up beam vertically
to avoid it trying to twist the truss. Fig. 29
13.8 Slings Fig. 27 - Two Connection Elements (13.7.6))
13.8.1 Caution: Slings apply compression to truss chords and should be
fitted at a node point that offers resistance to the compression.
13.8.2 The wider the sling angle the greater the compression applied.
13.8.3 Important; Polyester round slings spread load over a greater area
than a wire rope sling but are weakened by heat and can be
pinched or cut by connections between modules.
13.8.4 For Suggested ways to sling trusses see separate TSG load
booklet

14 Trusses and People

Fig. 28 - Slack Motors (13.7.8)
14.1 Important: Data in TSG load tables does not account for supporting
personnel.
14.2 Important: The Work at Height Regulations 2005 place duties on
employers to eliminate the need to work at height wherever possible, and
where it is necessary to prevent falls from occurring. The hierarchy of
control measures to prevent falls starts with platforms and ends with
‘climbing’ access as a last resort.
14.3 Fall Arrest
14.3.1 Danger: No account has been taken in TSG design calculations of
forces associated with the use of fall arrest equipment.
14.3.2 Important: The forces likely to be generated by any fall protection
system shall be checked by a competent person before being
attached to a TSG module.

Fig. 29 - Vertical pickups (13.7.9)

Page 16 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 14.3.3 The T2 system from the Total Solutions Group offers an
exceptionally strong structural system with a fall arrest facility
inbuilt by the manufacturer. This provides a safe system of work Span
when supported appropriately from a suitable structure.

15 Cantilever trusses
15.1 Extending a truss beyond a support creates a ‘cantilever’ which is less
Fig. 30 - Cantilever CPL
stable than a simple span. CPL EPL Load
(15.2)
15.2 Warning; Application of a point load to a cantilever should never exceed Load x 0.25
25% of the CPL of the back-span length, Fig. 30
15.3 Warning; Application of a uniform load to a cantilever should never
exceed 25% of the UDL of the back-span length, Fig. 31
Span
15.4 TSG structural reports conforming to EN17115 will always contain
cantilever loading data.

16 Curved and Circular trusses

16.1 Important: Circular trusses are not generic products.
UDL UDL Load
16.2 Warning: There is no loading information available without structural Fig. 31 - Cantilever UDL Load x 0.25
analysis. (15.3)

16.3 Warning: Do not refer to TSG generic truss load tables to determine
allowable loads on circular trusses.
Cantilever
16.4 Circular trusses intended to be flown horizontally should not be flown at
angles without consulting TSG.
16.5 The arc of a truss between support points is a cantilever. Therefore,
allowable loads must be determined prior to use by a competent person.
Fig. 32, When lifting truss circles aim to support them in as many places
as possible.
16.6 Warning: Do not try to lift or support a circular truss on fewer supports
than required by the structural analysis

Fig. 32 - Curved Trusses (16.5)

Page 17 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

17 Identification and Serial Numbers
17.1 Each truss and component have an identification mark unique to TSG.
17.2 The label is easily recognisable, durable and should not be obscured or
removed.
Unique identifying Product Code
17.3 The label includes the TSG name, type of module or component, month number
and year of manufacture, self-weight and the unique serial number and
barcode. Fig. 33
Date of issue of Economic Region
17.4 TSG Prefix codes for standard products are listed below: - product of manufacture

OV30 OV 30cm Square Truss XOS TFL XO Square

OV30L OV 30cm Ladder XOT TFL XO Tri
OV30T OV 30cm Tri. Truss LD12 TFL Light Duty Truss
OV40 OV 40cm Square Truss SLD TFL Serious Light Duty
OV40L OV 40cm Ladder MD TFL Medium Duty
OV40T OV 40cm Tri. Truss SMD TFL Serious Medium
Duty
LB Slick Litebeam HD TFL Heavy Duty Truss
LX Slick Litebox SHD TFL Serious Heavy Self-weight of
Duty individual module Product Logo
GL Slick GS Lite LAD Moving Light Truss
MB Slick Minibeam EHD TFL Extra Heavy Duty QR Code link to Product line brand
1G Slick GS Truss 12GST TFL 12” Tower Truss website
Unique identifying
NL Slick Nova Lite Truss 18GST TFL 18” Tower Truss
number
NO Slick Nova Beam Truss Company Logo

M Slick Maxibeam LAB Slick Lite Ladder EN standard for

5T Slick Superbeam SML Slick Mini Ladder Trading Company metallic products –
Types of inspection
5TCAT Slick Superbeam SL Slick Maxi Ladder
documents
Catwalk
LT Slick Lite Tower Fig. 33 – TSG Product Identification Label (17.3)
1TM Slick Litemast

Page 18 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

18 Wind loads
18.1 Important: Stability of structures can be affected indoors and outdoors by
changes in wind speed, direction and pressure. Fig. 34
18.2 Stability calculations must be carried by a competent person Wind
18.3 The appropriate structural report will contain instructions that must be
followed by the user.
Wind
18.4 Important: Reference should be made to ‘Temporary Demountable
Structures’

Wind
19 Earthing (Equipotential bonding)
19.1 Appropriate earth bonding shall be determined by a Competent Person.
19.2 The surface of the aluminium or steel shall be cleaned with wire wool to
remove the oxidisation on the surface before the earth clamps are fitted.
19.3 Caution: The User should note that there is not a proper connection
between the main grid structure and the towers in a ground support
structure as the grid is guided up and down the towers with nylon wheels.

20 Inspection and Maintenance

20.1 Important: These inspection criteria relate only to TSG manufactured
trusses. Fig. 34 - Wind Load Stability (18.1)
Multiple area Local area
20.2 Discard or Quarantine criteria; General
reductions of no reductions of no
20.2.1 Bent or deformed without load applied more than 15% more than 15%
20.2.2 Welds are incomplete or shows signs of cracking. Certain cracks
are associated with the manufacturing process. If in doubt,
consult TSG.
20.2.3 Wear on welds and welded areas.
20.2.4 Repairs made without written approval from TSG.
20.3 Discard or Quarantine criteria; Main members
20.3.1 Reduction of the total cross–sectional surface area by more than
15%, Fig. 35; or any local area reduction transverse to the tube
axis of more than 15%, Fig. 36.
20.3.2 Localised bending of one or more of the main tubes viewed from
the end of a section. Fig. 36 - Multiple Area Reduction Fig. 35 - Local Area Reduction
(20.3.1) (20.3.1)

Page 19 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 20.3.3 Damaged, partly missing or broken tubes.
20.3.4 Cracks or holes in the main tubes including drilled holes. D/10
20.3.5 Holes from the manufacturing process should not be considered
as damage
20.3.6 Lasting deformation through dents, lateral compression etc. that
D
results in a change of diameter (D) by more than 10%. e.g. Lite
Beam tube dia. = 48mm; 44mm minimum and 52mm maximum.
Fig. 37
20.4 Discard or Quarantine criteria; Lattice members
20.4.1 Reduction of the total cross-sectional surface area by more than
15%, Fig. 35, or any local area reduction transverse to the tube Fig. 37 – Dents (20.3.6)
axis of more than 15%. Fig. 36 D/10
D
20.4.2 Localised bending of one or more of the lattice tubes.
20.4.3 Damaged, missing, or broken lattice tubes.
20.4.4 Cracks or holes in the lattice tubes.
20.4.5 Holes from the manufacturing process should not be considered
as damage.
20.4.6 Lasting deformation through dents, lateral compression etc. that
results in a change of diameter by more than 10%. Fig. 37
20.5 Discard or Quarantine criteria; Connectors and connecting elements
Fig. 38 - Hole Elongation (20.5.1)
20.5.1 Deformation or elongation of connection holes (rivets, roll pins, in
gusset plates) in the fittings or the main tubes by more than 10%
e.g. Lite Beam 6.25mm + 0.63mm = 6.88mm max. Mini Beam,
GS Truss, Maxi Beam, Folding Truss 10mm + 1mm = 11mm.
Bending or deformation of any fitting part by more than 10
degrees from the axis of the main tubes. Fig. 38
20.5.2 Reduction of the cross-sectional area of the connector (male or D/10 D
female) surface by more than 10%. Fig. 39
20.5.3 Damaged connector or parts of the connector missing.
20.5.4 Damaged or missing roll pins or fixing rivets. Fig. 39 - Connector Reduction (20.5.2)

20.5.5 Fixing rivet should completely fill holes and have close contact
with the riveted surfaces
20.5.6 Diameter reduction of connector elements (truss pins or fixing
bolt) by more than 10%. Fig. 40

Page 20 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 20.5.7 No damage to the threads on fixing bolts
20.5.8 Clear (galvanic) corrosion on rivets or roll pins in the connectors.
20.6 Painting
20.6.1 Inspecting painted modules is difficult because paint can obscure D/10
surface defects and cracked welds. D
20.6.2 If a module is painted repeatedly defects may exist indefinitely.
20.6.3 Modules should always have previous layers of paint removed
Fig. 40 - Connecting Element Reduction (Pin) (20.5.6)
before any new painting occurs.
20.6.4 Modules should be re-inspected before new paint is applied.
20.6.5 Paint removal must not reduce the dimensions of any materials.
20.6.6 Warning: Chemical treatments damage aluminium. Do not use
chemical baths for paint-stripping.
20.7 Saline environment
20.7.1 If trusses are subjected to a salty atmosphere, then they should
be rinsed on a regular basis.
20.8 Corrosion
20.8.1 The contact surfaces of different metals should be checked for
corrosion, for example the bolts and their bearing surfaces.
20.9 Attention
20.9.1 Danger: Neglecting any of the above factors may result in
property damage, injury to people or death.
20.9.2 Important: Damaged modules should be clearly marked as such
and shall not be used under any circumstance. Any repair must
be undertaken by an authorized agent of TSG.
20.9.3 Important: If 3rd party inspections are checking welds then they
should only inspect TSG products if they are fully conversant with
the following:
• Execution class

• Consequence class

• Weld quality level

Page 21 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 20.9.4 Important: Aluminium Trusses should be inspected by, and in line
with an Examination Scheme drawn up by, a competent person
based on a Risk Analysis of usage.

21 Transportation, handling and storage

21.1 The trusses shall be loaded in such a way that they are not put under
undue or significant stress during transportation.
21.2 Take care to ensure that modules are not subjected to abrasion which
could result in loss of metal or other damage.
21.3 Do not allow load restraints to damage modules.
21.4 On no account shall trusses be dragged across the floor as this could
lead to abrasion of the chords, which would result in loss of metal, or
significant cuts, gouges or other damage which could result in stress
Avoid
concentrations and ultimately to stress fracturing.
braces
21.5 Take care where fork lifts are used to move modules.
21.6 Position the forks to avoid damage to the module, particularly the
diagonals. Fig. 41
21.7 When lifting equipment modules with fork lifts ensure that forks are
positioned as close to node points as possible.
Fig. 41 - Forklift Damage (21.6)
21.8 Stacks of modules should be supported off the ground at node points.
21.9 Take care to ensure stacks of modules remain stable. Fig. 42
21.10 Warning: Modules may be heavy enough to prevent safe manual
handling. Mechanical means are preferred.
21.11 The trusses shall not be stored outside unless they are adequately
protected from the elements.
21.12 Warning: Do not allow water ingress where there is a possibility of
freezing conditions
21.13 The user shall use adequate care when storing the trusses so that they
are not overstressed. For example, the trusses should not be stacked so
that the members or connections are bent or damaged.

Fig. 42 – Stacking (21.9)

Page 22 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

22 Spares and Replacement parts
22.1 There are no parts on a truss module that are replaceable by the user.

23 Disposal and Recycling

23.1 All Items of an aluminium or steel truss, unless otherwise stated, are
100% recyclable.

24 Product Specific information

24.1 Litebeam, Litebox, OV Truss Range Fig. 43 - Litebeam, Litebox and OV Range (24.1.1)
24.1.1 Warning; Do not support or apply load at the very end of a single
span. Fig. 43
24.2 GS Truss, Minibeam, Maxibeam and Superbeam
24.2.1 Warning; Side diagonal brace patterns must flow. Fig. 44
24.3 GS Truss (when used as a tower)
24.3.1 Warning; Hinge point must be on the supported end Fig. 45
24.4 Maxibeam Truss
24.4.1 Caution: Open bottom versions of Maxibeam must be fitted with
the appropriate number of snap braces. Example; a 2.4mt truss
should have 2 x snap braces. Fig. 46
Fig. 44 - GS Truss, Minibeam, Maxibeam and Superbeam (24.2.1)
24.5 Medium Duty Truss
24.5.1 Important; trusses pre-2017 have two bolt holes per gusset plate
i.e. 8 per face. Only the outer hole on each gusset is used for
connections. The inner hole serves no structural purpose. Fig. 47

25 List of Significant Hazards

25.1 Mechanical hazards due to:
25.1.1 Inadequate mechanical strength
25.1.2 Instability
25.1.3 Gravity and stability
Fig. 45 - GS Truss (when used as a tower) (24.3.1)
25.1.4 Height from the ground
25.1.5 Approach of moving elements to fixed parts

Page 23 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

 25.1.6 Slippery surface
25.1.7 Surface geometry
25.1.8 Potential energy
25.1.9 Sharp edges
25.2 Additional hazards and hazardous event due to lifting procedures, falling
loads, collisions due to: 2 x Snap
25.2.1 Gravity and stability hooks per
2.4mt truss
25.2.2 Incorrect loading
25.2.3 Unsuitable connection elements and accessories
25.2.4 Unsuitable selection of lifting devices, equipment and incorrect
integration
25.2.5 Incorrect installation, testing, use and maintenance Fig. 46 - Maxibeam Snap Braces (24.4.1)

25.2.6 Incorrect integration of machinery parts

25.2.7 Unintentional movement due to mechanical failure
25.3 Electrical hazards
25.3.1 Contact of persons with parts which have become live under faulty
conditions
25.4 Thermal hazards
25.4.1 Objects or materials with a high or low temperature Inside Holes
are not needed
25.5 Noise hazards
25.5.1 Mechanical noise
25.6 Vibration hazards
Outside Holes
25.6.1 Loosening of components due to dynamic actions
are for joining
25.7 Ergonomic hazards trusses
25.7.1 Poor body mechanics, posture or excessive effort
25.7.2 Inadequate working light Fig. 47 - Medium Duty Truss (24.5.1)

25.8 Hazards associated with the environment in which the product is used
25.8.1 Weather conditions (temperature, wind, ice, lightning etc.)
25.8.2 Seismic activity
25.8.3 Corrosion

Page 24 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

26 References
26.1 The structures and this manual have been designed using the latest
editions of all appropriate European Standards and British Standard
Codes of Practice. The principal codes are: -
• BS EN 1991; Actions on Structures Part 1-1; General actions –
Densities, Self-weights, imposed loads

• BS EN 1999; Design of Aluminium Structures Part 1-1; General structural

rules.

• BS EN 1993; Design of Steel Structures Part 1-8; Design of joints.

• BS 8118: Structural Use of Aluminium, Part 2; Specification for materials,

workmanship and protection (in older reports).

• EN 17115 Entertainment Technology – Specification for design and

manufacture of aluminium and steel trusses.

• Temporary Demountable Structures; Institute of Structural Engineers, UK

• BS EN 82079-1 2012 Preparation of instructions for use structuring,

content and presentation Part 1: General principles and detailed
requirements.

27 Inspection and Maintenance record

Date:

Inspector:

Inspection record document number:

Result: Passed / Failed

Notes:

Page 25 of 25 TSG TRUSS OPERATING MANUAL. VERSION 7A – 18TH JANUARY 2019

Total Solutions Group, Kingston Industrial Estate, 81 - 86 Glover Street, Birmingham, B9 4EN, England
T. +44 (0)121 772 5234 E. sales@trussing.com
www.trussing.com