Opera Leipzig

Stage Control System Refurbishment

The existing stage control system at the Leipzig Opera no longer met the operational requirements of daily performance use. Due to the age of the system, neither operational reliability nor the availability of spare parts could be ensured.

Our task was to develop the planning for a new, safe, and fully functional stage control system. Based on close coordination with the user, detailed site surveys, and our prior experience with the venue, we were able to produce a precise design and technical specification within a short timeframe. As a result, the refurbishment of the stage control system was successfully completed within the defined schedule and budget, carried out over two performance breaks.

Our specialist planning services were provided as part of ATI – Arbeitsgemeinschaft Theater Ingenieure.

Stage Control in the Spotlight

Overhead Stage Machinery with Batten and Point Hoists

For the existing 48 batten hoists and 12 point hoists, new control axes were installed. In addition, all existing brakes were replaced with brakes featuring air-gap monitoring, and load monitoring systems were added.

Upgrade: Powered Hoists Instead of Manual Counterweight Sets

To replace four manual counterweight sets in the rear stage area, four powered hoists were installed.

Lighting Battens with New Power Supply

The lighting battens were equipped with a new power feed.

Chain Hoists as Forestage Hoists

The forestage also received new hoisting equipment: eight new chain hoists were installed for lifting loads. These were fully integrated into the new stage control system.

Understage Machinery with Lift Platforms

The platform drives were also upgraded with new control axes. In total, two double-deck lift platforms, two single-deck platforms, and their associated compensation platforms received new control components.

Line-Shaft Hoists in the Platform Deck

The decks of the double-deck lift platforms are now equipped with an additional four line-shaft hoists, serving as installation and maintenance aids.

Stage Wagons

The Erfurt Theatre is equipped with three stage wagons and a three-part revolve wagon. The wagons are lowered via compensation platforms.

Stage Control System and Operator Consoles

At the core of the refurbishment is the renewal of the stage control system. Stage control systems are subject to stringent requirements regarding functionality and operational reliability. The new system complies with the relevant safety standards in accordance with SIL 3.

The control system operates 65 axes of overhead machinery and 14 axes of understage machinery.

A total of 12 new operator consoles were provided, including four main control desks and eight additional operator stations (such as follow-up consoles, test panels, and similar units).

Phased Implementation During Performance Breaks

The refurbishment of the stage control system and the upgrade of the overhead stage machinery were carried out in two construction phases during scheduled performance breaks. Ongoing theatre operations did not need to be interrupted for the execution of the works.

Secure and Compliant Use of Grant Funding

The project was financed through ERDF (European Regional Development Fund) grants. To ensure the proper and compliant use of these funds, stringent requirements were placed on both planning and execution. Our work on this project was reviewed by an independent expert assessor. As a result, our planning and implementation were fully validated, and the grant funding was disbursed in full.