Truss Your Heart

I love trusses…they’re just so expensive. When we bought our circular truss that we hang in the middle of our building…holding our projector and stage lights…we found the cheapest place to get it. We spent $1600 for a 13 foot diameter triangular circle truss. Pretty amazing, huh? Where did we get this amazing deal? I’m so glad you asked.

We bought our a few years ago from 123DJ. Their prices have gone up but they’re still pretty affordable. Cheap Lights is also another great site to buy trussing and other lighting fixtures from. So that’s that for trusses.

However, there is another alternative if you need a truss but don’t have the money to invest in them: antenna towers. These run for close to $100 for a 10 foot segment. You can pick these up in your local electronics store or order them online from a place like Antenna Systems or Warren Electronics. The pieces that look most like triangular trusses are called the Rohn 20G.

It’s important to note that these aren’t as “pretty” as the trusses you’ll buy from a stage design store. Also, these antenna towers are meant to hold vertical weight, not horizontal weight. So these should only be used for holding light-weight fixtures or used vertically.

One more option, if you’re going for the look rather than the function, is building your own trusses out of PVC pipes. You can attach them together and spray paint them with metallic paint. This is only advisable if you will be attaching no weight to them.

Understanding Truss Types for Church Stages

When selecting trusses for your church stage, understanding the different types available can help you make an informed decision that fits both your aesthetic vision and budget constraints. Box trusses feature four chords connected by diagonal bracing, creating a square or rectangular profile that offers excellent strength in all directions. These are ideal for hanging significant weight like LED video walls or heavy lighting rigs. Triangular trusses, also known as ladder trusses, have three chords and are lighter and more cost-effective, making them perfect for smaller lighting setups and decorative elements.

Circular trusses, like the one mentioned above, create stunning visual focal points and are particularly popular for center-stage installations. These can range from small 6-foot diameters to massive 20-foot spans, with prices scaling accordingly. Square trusses offer a modern, industrial aesthetic that works well in contemporary worship spaces. The choice between aluminum and steel trusses also impacts both cost and functionality—aluminum is lighter and easier to rig but more expensive, while steel offers maximum strength at a lower price point but requires more robust support structures.

Beyond the truss itself, consider the connection hardware. Different manufacturers use varying connection systems, from simple bolted plates to sophisticated spigot and pin systems. While spigot connections offer faster setup times, bolted connections often provide greater peace of mind for permanent installations. When budgeting, factor in not just the truss segments but also corners, base plates, and any custom fabrication needed for your specific stage geometry.

Installation Safety and Best Practices

Safety should be your paramount concern when installing trusses in a church environment. Always consult with a structural engineer before hanging any significant weight from your ceiling, especially in older buildings that may not have been designed with theatrical rigging in mind. The engineer can assess load-bearing capacity, identify suitable anchor points, and specify appropriate hardware for your specific situation.

When rigging trusses, use only certified rigging hardware rated for theatrical or entertainment use. Standard hardware store components are not designed for dynamic loads and can fail catastrophically under the vibration and movement common in live events. All rigging should be performed by qualified professionals who understand point load distribution, angle factors, and safety margins. Remember that a falling truss or light fixture can cause serious injury or death.

For churches without suitable ceiling structures, ground-supported truss towers offer a safer alternative. These systems use weighted bases or stage screw attachments to create freestanding structures that don’t rely on overhead rigging. While they consume floor space, they eliminate the risks associated with ceiling mounts and are often more affordable than structural reinforcement. Always follow manufacturer specifications for weight limits and never exceed rated capacities, even for temporary installations.

Related Designs

• Against the Ropes – Explore how rope and cable elements can create dynamic stage designs with structural visual interest similar to truss installations.
• Arrayed – Discover creative ways to arrange lighting and structural elements in repeating patterns for maximum visual impact.
• Pixel Perfect – See how LED panels and modern lighting integrate with stage structures to create immersive worship environments.
• Tall Columns – Learn about vertical stage elements that can complement or replace truss structures in your sanctuary design.
• Glowing in Circle – Find inspiration for circular stage elements that create focal points similar to circular truss installations.

Pro Tips for Truss Installations

Plan for Growth: When designing your truss layout, always install more capacity than you currently need. Churches frequently add lighting, video screens, and special effects over time. Installing additional truss segments or stronger rigging points during initial setup is far more cost-effective than retrofitting later. Consider future needs like Christmas productions, Easter pageants, and special events that may require additional hanging positions.

Label Everything: Create a detailed rigging plot that documents every connection point, weight load, and electrical run. Label each truss segment and connection clearly with permanent markers or engraved tags. This documentation becomes invaluable when troubleshooting issues, planning modifications, or training new volunteers. Keep digital copies of your rigging plots accessible to your technical team and update them whenever changes are made.

Inspect Regularly: Establish a quarterly inspection schedule for all trusses and rigging hardware. Look for signs of wear, corrosion, loose connections, or deformation. Pay special attention to areas near HVAC vents where temperature fluctuations can cause expansion and contraction. Document each inspection with photos and notes, and address any concerns immediately. Remember that prevention is always cheaper than replacement or repair after a failure.

Consider Modular Systems: For churches that reconfigure their stage frequently, invest in modular truss components that can be easily reassembled in different configurations. Quick-connect systems and pre-fabricated cable harnesses can reduce setup time from hours to minutes. This flexibility allows you to adapt your stage design for different sermon series, seasonal themes, and special events without major construction projects.

Related: White on White – See how a clean white stage with LED lighting creates a versatile worship environment perfect for any service style.