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Wire Rig Safety Engineering & Design Analysis

Analyze wire rig designs, calculate safety factors, and generate compliance documentation

3.9(35 reviews)
100+ downloads
Updated Oct 2026
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What You Can Do

You can submit wire rig designs, equipment specifications, and stunt parameters to receive detailed safety engineering analysis. Claude calculates actual vs. rated load capacities across multi-point rigging systems, identifies potential failure modes, flags compliance gaps, and generates formal safety reports ready for insurance and film commissions. This transforms conceptual designs into verified safety assessments before rigging setup begins.

Features

Load capacity calculations

Compute safety factors across cable, shackles, motors, and attachment points with industry-standard engineering margins

Multi-point rigging analysis

Evaluate complex anchor systems, suspension angles, and force distribution across multiple support structures

Failure point identification

Flag weak links, stress concentrations, and edge cases that could compromise system integrity

Equipment specification review

Assess cable ratings, hardware certifications, motor specifications, and control system redundancy

Compliance documentation

Generate formal safety reports, risk matrices, and mitigation plans aligned with OSHA, SAG-AFTRA, and local film commission requirements

Design comparison framework

Evaluate multiple rigging options side-by-side on safety, feasibility, and cost factors

Incident investigation support

Analyze equipment concerns and near-misses to determine root causes and preventive measures

Safety protocol gaps

Identify missing procedures, testing requirements, or contingency plans in existing rigging protocols

Example Output

Example 1: Cable Load Analysis

Input: 200 lb performer, 3-point aerial suspension with 3/8" aircraft cable, 45° angle rigging

Output:

  • Rated cable capacity: 5,400 lbs (working load limit)
  • Actual distributed load per cable: 77 lbs (at 45° angles)
  • Applied safety factor: 70:1
  • Assessment: ✓ EXCEEDS minimum 8:1 safety factor. Acceptable configuration.
  • Hardware cross-check: Shackle rating 4,500 lbs verified adequate.

Example 2: Risk Matrix

RiskProbabilityImpactMitigation
Cable abrasion at roof edgeMediumCatastrophicAdd edge guards, inspect cable every 10 takes
Motor control system failureLowSevereDual-circuit backup motor, manual descent capability
Rigging assistant errorMediumSevereChecklist protocol, certification requirement

Example 3: Compliance Gap Report

Missing items for SAG-AFTRA submission:

  • ☐ Third-party structural engineer sign-off for building attachment points
  • ☐ Load testing documentation for cable/hardware assembly
  • ☐ Emergency descent procedure with timing specifications
  • ☐ Rehearsal protocol with performer in full costume/makeup

Recommended: Complete items before talent call.

What's Included

  • SKILL.md instruction file: Full engineering workflow and safety framework
  • Load Capacity Calculation Template: Cable, shackle, and motor rating matrices with safety factor guidance
  • Multi-Point Rigging Analysis Checklist: Systematic review of anchor points, angles, and force distribution
  • Safety Report Framework: Formatted template for OSHA/SAG-AFTRA compliance documentation
  • Risk Assessment Matrix: Probability/impact grid for identifying and mitigating failure scenarios

Who It's For

  • Stunt coordinators — Pre-production rig analysis and safety documentation for aerial sequences
  • Production safety officers — Compliance verification and risk assessment for film/TV permits
  • Rigging crews — Design validation and load calculation verification before setup
  • Insurance and risk managers — Documentation support for underwriting aerial stunt coverage
  • Stunt performers — Understanding of rig safety parameters and design trade-offs

Best For

  • Wire rig design review and validation before production
  • Load capacity and safety factor calculations for multi-point suspension systems
  • Compliance documentation for OSHA, SAG-AFTRA, and local film commission requirements
  • Risk identification and mitigation planning for aerial stunt sequences
  • Equipment specification evaluation and design option comparison

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