Alustage Heavy Duty

Alustage Heavy Duty Trussing

Alustage Heavy Duty Trussing delivers a modular aluminium framework built to carry sizeable suspended loads in touring, corporate, broadcast, and installed environments. Manufactured in Europe from high-tensile alloy, each section slots together using the familiar Alustage conical coupler method, creating rigid lattice structures with impressive span capability while keeping overall self-weight manageable for transport crews.

Core Construction

Every length uses a four-chord arrangement with diagonally braced web members. The layout distributes tension and compression evenly across the profile, resulting in minimal deflection under working load. Primary tubes have generous wall thickness, providing notable resistance to buckling without adding unnecessary mass.

• Material: EN-AW 6082 T6 aluminium alloy
• Chord diameter range: 48 - 60mm (profile dependent)
• Web member diameter range: 20 – 30mm
• Standard finishes: natural mill or black powder coat
• Connection: conical sleeves, spigots, and safety pins supplied with each segment

Load Handling & Span Guidance

Engineering data supplied by the factory outlines uniformly distributed and point-load tables for every stock length. In practice, the system comfortably bridges eight to fourteen metres between supports when configured as a single beam, while grid or tower formats allow far greater clear spans. Deflection limits are calculated using a 1/200 span ratio unless local regulations stipulate tighter tolerances.

Factors Influencing Capacity

1. Total applied mass, including static fixtures and dynamic movement of automated luminaires
2. Distribution of weight along the beam or grid
3. Environmental forces such as wind uplift on outdoor structures
4. Number and location of joints, corners, and lifting points
5. Support conditions – ground-stacked towers, roof purlins, or flown motors

Comprehensive assessment by a competent rigger or structural engineer remains essential before final sign-off. Stage Concepts offers calculation assistance and can review drawings to ensure conformity with regional safety codes.

Module Variants

The catalogue contains straight lengths from 0.25 m up to 4 m, plus specialist components for directional changes or non-linear runs:

• Two-way, three-way, and four-way junction blocks
• Adjustable angles for irregular geometries
• Horizontal and vertical curved sections (custom radii available)
• Baseplates with integrated sleeves for tower builds
• Spacer pieces for fine-tuning overall dimensions

Every component aligns with the same coupler pattern, encouraging fast on-site assembly and simplified spare-part stock management.

Application Areas

Because of its mix of strength and portability, Alustage Heavy Duty Trussing is visible across a wide range of disciplines:

Advantages for Production Teams

• Consistent manufacturing tolerances simplify mixing new and legacy stock
• Straightforward inspection routines; visual checks for dents and connector wear take seconds
• Certificated supporting documentation assists with permitting and insurance submissions
• Wide accessory ecosystem reduces the need for custom adapters
• Light weight relative to steel alternatives eases manual handling and lowers trucking costs

Care & Maintenance

Routine upkeep largely involves basic visual inspection. Look for crushed chords, cracked welds, and elongation around connector holes. Components showing damage beyond cosmetic scratching must be removed from service until a qualified technician deems them safe. After exposure to moisture or coastal environments, rinse with fresh water and dry thoroughly before storage to slow oxidisation. Factory touch-up paint is available for powder-coated items.