Building a Frame

I had originally planned to use trussing to support the lights and had planned to use this to secure the PIR detectors in position and also to cable tie the wiring to. Although this would probably have been the easiest option considering it is the standard for stage lights, such as the follow spots that I plan to use. I was considering methods of how I would be able to hide or cover the trussing so that all it is not completely visible, and consequently will make it appear that the lights are coming out a blank space. I don’t want the technologies and equipment behind the project to be visible, as I feel that it will cause distraction from the light and the relationship between the user and the light. Although, as mentioned earlier, interaction cannot not be entirely sub-conscious I would like to remove the idea of ‘communication with a machine’ as much as possible. As a result I have decided to construct a platform the can be suspended that will house most of the equipment involved with the project. This will include, the lights, the PIR detectors, the wiring, the DMX controller, the PIR controller and the laptop that will control all of the processes. Although this may sound like a lot of equipment to secure, it is relatively lightweight, and should not pose a problem in terms of weight.

The structure will be similar to the flats that are used in the university studios, but will be slightly smaller and more lightweights. The structure will be built out 37mm by 63mm (approximately 1.5 inches by 2.5inches) CLS construction timber, which is extremely sturdy, and supportive. The beams will be 2400mm in length (which is approximately 7"10) and will form a square. Four extra beams that will be secured across the width will then support the square. Over this beamed structure I will secure 6mm plywood boards, acting as a skin upon which the equipment can be secured. Holes will then be cut into this skin, which will allow the lights, which are secured above, to emit the beam. In order for this to be safe as possible batons will be used to securely hold the lights in place. The entire structure will then be supported from the ceiling via welded steel chains that will be connected to the structure with 30mm steel hooks. The structure will be made in a way that will enable it to disassemble easily and then be reassembled once in the studio. This will be made easy by cross dowelling bolts. All of the equipment that is necessary for this to be built is available at Homebase or B&Q. I will then paint the underside of the structure in matt black paint so that it is more camouflaged with the darkness of the structure. Fortunately for me my stepfather is a budding carpenter and offered to help with the construction of the structure. This was beneficial, as although the build would not have been too complicated to produce it would mean that it would be as safe as possible. Health and safety is a big consideration for a structure such as this, something that will be considered later in this text.

Pricing:

Here is a breakdown of the pricing of the materials needed for the structure:

CLS construction timber beams: £1.79 each £1.79 x 8 = £14.32 (homebase)
Welded steel chains: 10m x 8mm = £14.49 each (screwfix)
6mm Plywood Sheets: 2440 x 1220 = £14.86 x 2 = £29. 72 (homebase)
Cross dowelling bolts: £1.90 per pack of 50 (screwfix)
Cross dowels: £1.99 per pack of 50 (screwfix)
Steel Hooks: £2.29 per pack of 5 (used 8) £2.29 x 2 = £4.58 (screwfix)
Black fabric: £18.00 (Matalan)

TOTAL: £85.00

Construction:

1) As the wood already came in lengths of 2400m this dictated the size of structure. In order to produce a square Cut the two side lengths slightly shorted enabling the pieces to be bolted together.

2) Cut recesses (grooves) in left and right lengths, which the cross middle support could then be supported in.





3) Repeated this process with the other two supports.



4) Bolted in position with cross dowels, allowing for easy disassemble.

5) Attached plywood skin to the structure using screws



6) Added small feet to the underside of the structure to allow the platform to be raised slightly of the ground, which prevented the PIR detectors from being damaged.

Health and Safety:

As you can probably imagine there are large health and safety risks associated with a structure such as this, especially considering that it will be hanging from a ceiling and users will walk underneath it. In order to properly assess this I contacted Robert Belton who is the studio manager and organised a meeting between, him, John Viney (the set technician) and myself.

The weight of the structure is the main determining factor of safety and how the structure can be supported from the ceiling. In order to consider this I need to consider the total weight of what would need to be supported. Firstly each light is 10kg (30kg for all lights), the PIR detectors are 80g each (400g for all PIR detectors), the laptop that will be used is approximately 3kg, the structure is wooden structure is 40kg, and I would allow for additional 5kg to cover the weight of both controllers, the wiring, batons to hold the lights in place, power cables, extension leads and everything else that would be housed on top of the structure. The total of all of this comes to 78.4kg, which I will round up to 80kg, to be extra safe.

This is a generous calculation, as I think that it is better to be over the actual weight than under, as any calculations considering the supports will then certainly be safe.